MLT 742 H T LS, Mt1033 HLT S2e2 S3e2 Repair Manual 547946en

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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GENERAL INSTRUCTIONS AND SAFETY NOTICE
Group 00 (General characteristics and safety) 1-1
ENGINE
Gruppe 10 (Motor) 2-1
AXLE ASSEMBLY - AXLE

Group 30 (Axle) 3-1
HYDRAULIC
Group 70 (Hydraulic) 4-1
TRANSMISSION
Group 75 (Hydrostatic) 5-1
ELECTRICITY
Group 80 (Electricity) 6-1
GROUP 0
GENERAL POINTS
LIFT TRUCK CHARACTERISTICS
0-1-M125 EN
MLT 742 H T LSU

MT 1033 HLT Série 2-E2
10 / 12 / 2007
2
TABLE OF CONTENTS
CHARACTERISTICS 4
DIMENSIONS AND LOAD CHART 12
FILTERS CARTRIDGES AND BELTS 14
LUBRICANTS AND FUEL 16
3
CHARACTERISTICS MLT 742 H Turbo LSU Série 2-E2
I.C. ENGINE
- Type PERKINS 1104C-44T RG81374
- Number of cylinders 4 in line
- Number of strokes 4
- Suction Turbocharged
- Injection system Direct
- Ignition sequence 1.3.4.2.
- Clearance of rocker valve (cold)
. Inlet 0,20 mm
. Exhaust 0,45 mm
- Capacity 4400 cm3
- Bore 105 mm
- Stroke 127 mm
- Compression ratio 17,5/1
- Nominal rating loaded 2200 rpm
- Rating slow unladen 850 ± 20 rpm
- Max. rating unladen 2355 rpm
- Power ISO/TR 14396 101 cv/74,5 kw
- Maximum torque ISO/TR 14396 412 Nm at 1400 rpm
- Air cleaner Dry 3 µ
COOLING CIRCUIT
- Type By water
- Fan Puller
. Number of blades 10
. Diameter 508 mm
- Thermostat
. Start opening 77 °C to 85 °C
. Full opening 92 °C to 98 °C
HYDROSTATIC TRANSMISSION
HYDROSTATIC PUMP
- Type MANNESMANN REXROTH A4VG71DA1D7/32R with variable cubic
capacity and with automatic power governor
- Gear reverser Electromagnetic 12V
. Number of forward gears 4 (2 low 2 speed)
. Number of reverse gears 2 (2 speed)
- Main pump
. Max./Mini displacement 0 to 71 cm3/r
. Max. flow rate 170 L/mn
. Working pressure 470 Bar
- Boost pump
. Displacement 19,6 cm3
. Boost pressure Max. R.P.M. 28 ±2 Bar (transmission in neutral)
HYDROSTATIC MOTOR
- Type MANNESMANN REXROTH A6VM107DA2/63W with variable cubic capacity
GEAR BOX
- Type DANA
4
FRONT AXLE
- Type DANA
- Limited slip differential 45 %
- Hub reducers Epicyclic
REAR AXLE
- Type DANA
BRAKE
- Service brake Foot pedal. Hydraulic servo-brake, applied on the front and rear wheels.
. Type Multidisc brake immersed in oil.
- Parking brake Mechanical hand lever applied on the front wheels.
ELECTRIC CIRCUIT
- Earth Negative
- Battery 12 V - 105 Ah - 680 A EN
- Alternator 12 V - 75 A
. Type Denso A115i
. Tension regulator Incorporated into the alternator
- Starter 12 V - 3,0 kW
. Type Denso E95RL
5
FRONT AND REAR TYRES

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
FRONT UNLADEN 1600 KG KG/CM2 KG/CM2 CM2 CM2
400/80-24 156A8 PIA
FRONT LADEN 5100 KG KG/CM2 KG/CM2 CM2 CM2
TUBELESS 3,8 BAR
REAR UNLADEN 2200 KG KG/CM2 KG/CM2 CM2 CM2
BF GOODRICH REAR LADEN 800 KG KG/CM2 KG/CM2 CM2 CM2
FRONT UNLADEN 1600 KG 5,30 KG/CM2 1,84 KG/CM2 302 CM2 870 CM2
14,9X24 T35 STABILARGE 18PR FRONT LADEN 5100 KG 9,44 KG/CM2 3,29 KG/CM2 538 CM2 1552 CM2
3,6 BAR
DUNLOP REAR UNLADEN 2200 KG 6,58 KG/CM2 2,25 KG/CM2 333 CM2 975 CM2
REAR LADEN 800 KG 4,73 KG/CM2 1,67 KG/CM2 169 CM2 480 CM2
400/70-20 T37 150B 14PR
FRONT LADEN 5100 KG 12,15 KG/CM2 3,67 KG/CM2 420 CM2 1388 CM2
TUBELESS 3,8 BAR
REAR UNLADEN 2200 KG 8,50 KG/CM2 2,73 KG/CM2 258 CM2 803 CM2
DUNLOP REAR LADEN 800 KG 6,50 KG/CM2 2,09 KG/CM2 123 CM2 383 CM2
440/70-24 T37 147B
TUBELESS 2,8 BAR
15,5/80-24 SGI 12PR
TUBELESS 4 BAR
GOODYEAR REAR LADEN 800 KG 7,50 KG/CM2 2,07 KG/CM2 80 CM2 290 CM2
460/70R24 IT520 150A8
TUBELESS 3,3 BAR
445/70R24 MPT IT510 151G
TUBELESS 4,1 BAR
17,5LR24 XM27 145A8
TUBELESS 3,5 BAR
MICHELIN REAR LADEN 800 KG 0,87 KG/CM2 0,84 KG/CM2 920 CM2 953 CM2
15,5R25 XHA
TUBELESS 3,5 BAR
MICHELIN REAR LADEN 800 KG KG/CM2 KG/CM2 CM2 CM2
FRONT UNLADEN 1600 KG 1,60 KG/CM2 1000 CM2
445/70R24 XM47 151G
FRONT LADEN 5100 KG 2,85 KG/CM2 1788 CM2
TUBELESS 3,2 BAR
REAR UNLADEN 2200 KG 1,81 KG/CM2 1213 CM2
MICHELIN REAR LADEN 800 KG 1,14 KG/CM2 700 CM2
440/70R24 XM37 150A8-147B
TUBELESS 3,5 BAR
460/65R24 SF TRI STEEL
TUBELESS 3,8 BAR
NOKIAN REAR LADEN 800 KG KG/CM2 KG/CM2 CM2 CM2
500/65R24 TR FOREST MULTIPLUS
TUBELESS 3,2 BAR
REAR UNLADEN 2200 KG 2,27 KG/CM2 959 CM2
NOKIAN REAR LADEN 800 KG 1,47 KG/CM2 545 CM2
500/65R24 IND. AGRO
TUBELESS 3 BAR
6
HYDRAULIC CIRCUIT
- Type of pump Gear pump with flow divider
. Capacity 63 cm3
. Max. rating capacity unladen 148 L/mn
. Flow rate at 2300 rpm 145 L/mn
- Pressure
. Lifting, tilting, telescoping, attachment circuit 270 Bar
. Steering circuit 140 Bar
- Filtration
. Return 15 µm
. Suction 125 µm
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA 81 dB
(according to standard prEN 12053: 1995)
- Level of sound power in the LwA environment 106 dB

(according to directive 2000/14/EC modified by directive 2005/88/EC)
- Average weighted acceleration on driver's body m/s2

(according to standard NF EN 13059)
- The average weighted acceleration trannsmitted to the driver's
hand/arm system (in accordance with ISO 5349-2) is less than 2.5 m/s2
- Speed of movement of lift truck in standard configuration on horizontal ground

(except particular conditions)
. Forward unladen 28,8 km/h
. Reverse unladen 28,8 km/h
- Standard lift height 6840 mm
- Rated capacity with standard attachment 4200 kg
- Load center 500 mm
- Weight of forks (each) 71 kg
- Lifting motions (jib retracted)

. Unladen lifting 7,0 s 39,3 m/mn
. Laden lifting 7,5 s 36,7 m/mn
. Unladen lowering 5,3 s 51,9 m/mn
. Laden lowering 5,2 s 52,9 m/mn
- Telescoping motions (lifting jib)

. Unladen extending 8,2 s 19,8 m/mn
. Laden extending 9,0 s 18,0 m/mn
. Unladen retracting 6,2 s 26,1 m/mn
. Laden retracting 6,0 s 27,0 m/mn
- Reverse tilt time unladen 3,5 s 41,6 °/s
- Forward tilt time unladen 3,0 s 48,6 °/s
- Lift truck weight with standard attachment

. Unladen 7600 kg
. Rated load 11800 kg
- Axle weight with attached equipment (transport position)

. Front unladen 3240 kg
rated load 10225 kg
. Rear unladen 4360 kg
rated load 1575 kg
- Tensible strain at coupling hook

. Unladen 6000 daN
. Rated load 8350 daN
- Break out force with bucket 5550 daN

(according to standard ISO 8313)
7
CHARACTERISTICS MT 1033 HL Turbo Série 2-E2
I.C. ENGINE
. Inlet 0,20 mm
. Exhaust 0,45 mm
- Capacity 4400 cm3
- Bore 105 mm
- Stroke 127 mm
COOLING CIRCUIT
- Type By water
- Fan Puller
. Diameter 508 mm
- Thermostat
HYDROSTATIC PUMP
- Type MANNESMANN REXROTH A4VG71DA1D7/32R with variable cubic capacity
and with automatic power governor
- Main pump
- Boost pump
HYDROSTATIC MOTOR
GEAR BOX
- Type DANA
8
FRONT AXLE
- Type DANA
REAR AXLE
- Type DANA
BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
ELECTRIC CIRCUIT
- Earth Negative
- Battery 12 V - 110 Ah - 750 A EN
. Type Denso A115i
. Type Denso E95RL
9

18-19,5 16PR I224
TUBELESS 5 BAR
ALLIANCE REAR LADEN 1050 KG 2,59 KG/CM2 1,09 KG/CM2 406 CM2 960 CM2
400/80-24 156A8 PIA
TUBELESS 3,4 BAR
14,9X24 T35 STABILARGE 18PR FRONT LADEN 4500 KG 9,34 KG/CM2 3,10 KG/CM2 482 CM2 1450 CM2
3,4 BAR
DUNLOP REAR UNLADEN 2200 KG 6,47 KG/CM2 2,22 KG/CM2 340 CM2 990 CM2
REAR LADEN 1050 KG 4,98 KG/CM2 1,72 KG/CM2 207 CM2 600 CM2
400/70-20 T37 150B 14PR
TUBELESS 3,3 BAR
440/70-24 T37 147B
TUBELESS 2,8 BAR
400/80-24 T37 153B
TUBELESS 3,2 BAR
15,5/80-24 SGI 12PR
TUBELESS 4 BAR
460/70R24 IT520 150A8
TUBELESS 3,3 BAR
445/70R24 MPT IT510 151G
TUBELESS 4,1 BAR
15,5-25 12PR SGL DL 2A
TUBELESS 3,25 BAR
GOODYEAR REAR LADEN 1050 KG KG/CM2 KG/CM2 CM2 CM2
17,5LR24 XM27 145A8
TUBELESS 3,5 BAR
15,5R25 XHA
TUBELESS 3,5 BAR
460/70R24 XMCL 159A8
TUBELESS 3,4 BAR
10
HYDRAULIC CIRCUIT
. Capacity 43,8 cm3
- Pressure
. Lifting, tilting, telescoping, tilting corrector, attachment 270 Bar
circuit
- Filtration
. Return 15 µm
. Suction 125 µm
SPECIFICATIONS


- The average weighted acceleration trannsmitted to the driver's
- Speed of movement of lift truck in standard configuration on horizontal

ground (except particular conditions)
. Forward unladen 28 km/h
. Reverse unladen 28 km/h


- Reverse tilt time unladen 3s 41,9 °/s

. Unladen 7845 kg

rated load 9045 kg
rated load 2100 kg

. Unladen 6300 daN

(according to standard iso 8313)
11
DIMENSIONS AND LOAD CHART MLT 742 H Turbo LSU Série 2-E2
A 1200 mm
B 2560 mm
C 1142 mm
C1 1245 mm
D 4491 mm
D1 4594 mm
MLT742 D2 3949 mm
50° 60° 62° E 5691 mm
8 F 1870 mm
F1 1870 mm
40°
7
G 455 mm
6,84
G1 440 mm
6
G2 440 mm
I 789 mm
30° J 865 mm
5
K 1260 mm
L 45 mm
4
N 1720 mm
4200Kg
3000Kg
20° O 125 mm
2500Kg
3
2000Kg
P2 47,5 °
P3 53 °
1500Kg
2
10° R 3475 mm
S 7324 mm
1
T 3380 mm
N°244634
0° U1 2300 mm
0m
-3° 0.5m U2 2550 mm
5 4 3 2 1 0m V 4630 mm
3,93 3,10 2,03 1,25
2,52 1,50 V1 1250 mm
SUIVANT NORME EN 1459 annexe B. V2 3703 mm
W 2325 mm
Y 12,3 °
Z 133,5 °
12
DIMENSIONS AND LOAD CHART MT 1033 HL Turbo Série 2-E2
A 1200 mm
B 2810 mm
C 1393 mm
C1 1482 mm
D 4966 mm
D1 5055 mm
D2 4158 mm
E 6166 mm
MT1033HL F 1846 mm
50° 60° 60.5° F1 1846 mm
G 455 mm
40° 10
9,61 G1 440 mm
9 G2 440 mm
H 10 °
8
H1 10 °
30°
7 I 763 mm
J 865 mm
6
K 1040 mm
5 L 45 mm
3300kg
20° N 1690 mm
2500kg
4
2000kg
O 125 mm
1500kg
1200kg
3 P2 38 °
900kg
550kg
10° P3 53 °
2
600kg
R 3610 mm
1 S 7815 mm
0° T 3565 mm
N°241103
0m
0.5m
U1 2300 mm
-5.5°
-1 U2 2550 mm
7 6 5 4 3 2 1 0m
V 4925 mm
7,06 5,60 4,68 3,29 2,05
6,80 4.08 2,73 1,43 V1 1360 mm
W 2261 mm
Y 11,9 °
Z 113,7 °
13
FILTERS CARTRIDGES AND BELTS MLT 742 H Turbo LSU Série 2-E2
I.C. ENGINE
I.C. ENGINE OIL FILTER
ALTERNATOR BELT
Part number: 476954
Part number: 605041
Change: 500 H
DRY AIR FILTER CARTRIDGE

Part number: 563416 FAN BELT
Clean: 50 H* Part number: 257524
Change: 500 H*
SAFETY DRY AIR FILTER CARTRIDGE COMPRESSOR BELT

Part number: 563415 (OPTION AIR CONDITIONING)
Change: 1000 H* Part number: 244237
FUEL FILTER CARTRIDGE CYCLONIC PREFILTER

Part number: 605013 Part number: 224713
Change: 500 H Clean: 10 H
AUTOMATIC VACUUM-CLEANING PRE-FILTER

(OPTION)
Part number: 226611
*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.
TRANSMISSION
HYDRAOSTATIC TRANSMISSION OIL FILTER CARTRIDGE (15µ)
Part number: 236095
Change: 500 H
HYDRAULIC
HYDRAULIC RETURN OIL FILTER CARTRIDGE (15µ) SUCTION STRAINER FOR HYDRAULIC OIL TANK
DISTRIBUTOR CONTROL HEAD FILTER

FILTER CAP FOR HYDRAULIC OIL TANK
(from machine no 213285)
Part number: 62415
Part number: 254780
Change: 1000 H
Change: 1000 H
CAB
CAB VENTILATION FILTER (WITH AIR CONDITIONING)
CAB VENTILATION FILTER (WITHOUT AIR CONDITIONING)
Part number: 225052
Part number: 225052
Clean: 50 H
Clean: 500 H
Change: 250 H
14
FILTERS CARTRIDGES AND BELTS MT 1033 HL Turbo Série 2-E2
I.C. ENGINE

ALTERNATOR BELT
Part number: 476954
Part number: 605041
Change: 500 H

Change: 500 H*

FUEL FILTER CARTRIDGE CYCLONIC PRE-FILTER

AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION)

Part number: 226611
TRANSMISSION
HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE (15µ)

Part number: 236095
Change: 500 H
HYDRAULICS

Part number: 62415
Change: 1000 H
CAB
Part number: 225052
Part number: 225052
Clean: 50 H
Clean: 500 H
Change: 250 H
15
LUBRICANTS AND FUEL MLT 742 H Turbo LSU Série 2-E2
USE THE RECOMMENDED LUBRICANTS AND FUEL:

- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.
DIAGNOSTIC ANALYSIS OF OILS

If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle
oils may be requested depending on the rate of use.
(*) FUEL CHARACTERISTICS

Use a high-quality fuel to obtain optimal performance of the I.C. engine.
CHARACTERISTICS OF RECOMMENDED FUEL:

• DERV to EN590
• BS2869 Class A2
• ASTM D975 - 91 Class 2D
• JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.
I.C. ENGINE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5 L. 661706
I.C. ENGINE 11 Liters MANITOU Oil 20 L. 582357
API CH4 55 L. 582358
209 L. 582359
2 L. 473076
Cooling liquid
5 L. 470077
(protection - 30°)
20 L. 470078
COOLING CIRCUIT 21 Liters
2 L. 554002
Cooling liquid
5 L. 554003
(protection - 25°)
20 L. 554004
FUEL TANK 120 Liters Diesel fuel (*)
TRANSMISSION
2 L. 499237
MANITOU Oil
20 L. 546330
REDUCTION GEAR BOX 2 Liters SAE80W90
55 L. 546221
Mechanical transmission
209 L. 546220
400 g. 161589
1 Kg. 554973
MANITOU Grease
TRANSMISSION UNIVERSAL JOINT 5 Kg. 554974
Multipurpose HD NLGI 2
20 Kg. 499233
50 Kg. 489670
JIB
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g. 545996
MANITOU Grease
JIB PADS 1 Kg. 161590
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
MANITOU Grease
GREASING OF THE JIB 5 Kg. 554974
20 Kg. 499233
50 Kg. 489670
HYDRAULIC
5 L. 545500
MANITOU Oil 20 L. 582297
HYDRAULIC OIL TANK 131 Liters
Hydraulic ISO 46 55 L. 546108
209 L. 546109
16
BRAKE
MANITOU Oil
BRAKE CIRCUIT 1 L. 490408
Mineral brake fluid
CAB
400 g. 161589
1 Kg. 554973
MANITOU Grease
CAB DOOR 5 Kg. 554974
20 Kg. 499233
50 Kg. 489670
1 L. 490402
WINDSCREEN WASHER TANK Windscreen washer fluid
5 L. 486424
FRONT AXLE
5 L. 545976
MANITOU Oil
FRONT AXLE DIFFERENTIAL 7,2 Liters 20 L. 582391
Special immersed brakes
209 L. 546222
2 L. 499237
MANITOU Oil
20 L. 546330
FRONT WHEELS REDUCERS 0,75 Liter SAE80W90
55 L. 546221
209 L. 546220
400 g. 545996
MANITOU Grease
FRONT WHEELS REDUCERS PIVOTS 1 Kg. 161590
Multipurpose NLGI 2
50 Kg. 499235
REAR AXLE
5 L. 545976
MANITOU Oil
REAR AXLE DIFFERENTIAL 7,2 Liters 20 L. 582391
209 L. 546222
2 L. 499237
MANITOU Oil
20 L. 546330
REAR WHEELS REDUCERS 0,75 Liter SAE80W90
55 L. 546221
209 L. 546220
400 g. 545996
MANITOU Grease
REAR WHEELS REDUCERS PIVOTS 1 Kg. 161590
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
MANITOU Grease
REAR AXLE OSCILLATION 5 Kg. 554974
20 Kg. 499233
50 Kg. 489670
17
LUBRICANTS AND FUEL MT 1033 HL Turbo Série 2-E2




• DERV to EN590
• BS2869 Class A2
I.C. ENGINE
5 L. 661706
I.C. ENGINE 11 Liters MANITOU Oil 20 L. 582357
API CH4 55 L. 582358
209 L. 582359
2 L. 473076
Cooling liquid
5 L. 470077
(protection - 30°)
20 L. 470078
2 L. 554002
Cooling liquid
5 L. 554003
(protection - 25°)
20 L. 554004
TRANSMISSION
2 L. 499237
MANITOU Oil
20 L. 546330
55 L. 546221
209 L. 546220
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
JIB
400 g. 545996
MANITOU Grease
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
HYDRAULIC
5 L. 545500
209 L. 546109
18
BRAKE
MANITOU Oil
Mineral brake fluid
CAB
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
1 L. 490402
5 L. 486424
FRONT AXLE
5 L. 545976
MANITOU Oil
209 L. 546222
2 L. 499237
MANITOU Oil
20 L. 546330
55 L. 546221
209 L. 546220
400 g. 545996
MANITOU Grease
Multipurpose NLGI 2
50 Kg. 499235
REAR AXLE
5 L. 545976
MANITOU Oil
209 L. 546222
2 L. 499237
MANITOU Oil
20 L. 546330
55 L. 546221
209 L. 546220
400 g. 545996
MANITOU Grease
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
CHASSIS
PARTS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g. 161589
1 Kg. 554973
TILT CORRECTOR MANITOU grease
5 Kg. 554974
20 Kg. 499233
50 Kg. 489670
19
20
LIFT TRUCK CHARACTERISTICS
0-1-M143 EN
MLT 742 H T LS
MT 1033 HLT Série 3-E2
10 / 12 / 2007
2
TABLE OF CONTENTS
CHARACTERISTICS 4
DIMENSIONS AND LOAD CHART 10
FILTERS CARTRIDGES AND BELTS 12
LUBRICANTS AND FUEL 14
3
CHARACTERISTICS
I.C. ENGINE
. Inlet 0,20 mm
. Exhaust 0,45 mm
- Capacity 4400 cm3
- Bore 105 mm
- Stroke 127 mm
COOLING CIRCUIT
- Type By water
- Fan Puller
. Diameter 508 mm
- Thermostat
HYDROSTATIC PUMP
- Type MANNESMANN REXROTH A4VG71DA1D7/32R with variable cubic
capacity and with automatic power governor
- Main pump
- Boost pump
HYDROSTATIC MOTOR
GEAR BOX
- Type DANA
4
FRONT AXLE
- Type DANA
REAR AXLE
- Type DANA
BRAKE
MLT 742 H Turbo LSU Série 3-E2
- Brake circuit
. Pressure 27 Bar
. Displacement On boost hydrostatic pump.
- Service brake Foot pedal. Hydraulic servo-brake, applied on the front and rear wheels.
MT 1033 H L Turbo Série 3-E2

- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
ELECTRIC CIRCUIT
- Earth Negative
- Battery 12 V - 110 Ah - 750 A EN
. Type Denso A115i
. Type Denso E95RL
5

400/80-24 156A8 PIA
TUBELESS 3,8 BAR REAR UNLADEN 2200 KG KG/CM2 KG/CM2 CM2 CM2
14,9X24 T35 STABILARGE
18PR 3,6 BAR REAR UNLADEN 2200 KG 6,58 KG/CM2 2,25 KG/CM2 333 CM2 975 CM2
400/70-20 T37 150B 14PR
TUBELESS 3,8 BAR REAR UNLADEN 2200 KG 8,50 KG/CM2 2,73 KG/CM2 258 CM2 803 CM2
440/70-24 T37 147B
15,5/80-24 SGI 12PR
TUBELESS 4 BAR REAR UNLADEN 2200 KG 8,72 KG/CM2 2,35 KG/CM2 251 CM2 931 CM2
460/70R24 IT520 150A8
445/70R24 MPT IT510 151G
17,5LR24 XM27 145A8
15,5R25 XHA
445/70R24 XM47 151G
TUBELESS 3,2 BAR REAR UNLADEN 2200 KG 1,81 KG/CM2 1213 CM2
MICHELIN REAR LADEN 800 KG 1,14 KG/CM2 700 CM2
440/70R24 XM37 150A8-147B
460/65R24 SF TRI STEEL
500/65R24 TR FOREST MULTIPLUS
TUBELESS 3,2 BAR REAR UNLADEN 2200 KG 2,27 KG/CM2 959 CM2
NOKIAN REAR LADEN 800 KG 1,47 KG/CM2 545 CM2
500/65R24 IND. AGRO
TUBELESS 3 BAR REAR UNLADEN 2200 KG KG/CM2 KG/CM2 CM2 CM2
6
HYDRAULIC CIRCUIT
. Displacement 63 cm3
- Pressure
. Lifting, tilting, telescoping, attachment circuit 270 Bar
- Filtration
. Return 15 µm
. Suction 125 µm
SPECIFICATIONS


- The average weighted acceleration transmitted to the driver's hand/arm
system (in accordance with ISO 5349-2) is less than 2.5 m/s2

. Front unladen 25 km/h
. Rear unladen 25 km/h


- Reverse tilt time unladen 3,5 s 41,6 °/s

. Unladen 7600 kg

rated load 10225 kg
rated load 1575 kg

. Unladen 6000 daN

7

18-19,5 16PR I224
ALLIANCE REAR LADEN 1050 KG 2,59 KG/CM2 1,09 KG/CM2 406 CM2 960 CM2
400/80-24 156A8 PIA
14,9X24 T35 STABILARGE
18PR 3,4 BAR REAR UNLADEN 2200 KG 6,47 KG/CM2 2,22 KG/CM2 340 CM2 990 CM2
400/70-20 T37 150B 14PR
440/70-24 T37 147B
400/80-24 T37 153B
15,5/80-24 SGI 12PR
460/70R24 IT520 150A8
445/70R24 MPT IT510 151G
15,5-25 12PR SGL DL 2A
GOODYEAR REAR LADEN 1050 KG KG/CM2 KG/CM2 CM2 CM2
17,5LR24 XM27 145A8
15,5R25 XHA
460/70R24 XMCL 159A8
8
HYDRAULIC CIRCUIT
- Pressure
. Lifting, tilting, telescoping, tilting corrector, attachment circuit 270 Bar
- Filtration
. Return 15 µm
. Suction 125 µm
SPECIFICATIONS


- The average weighted acceleration transmitted to the driver's

. Front unladen 25 km/h
. Rear unladen 25 km/h


- Reverse tilt time unladen 3s 41,9 °/s

. Unladen 7845 kg

rated load 9045 kg
rated load 2100 kg

. Unladen 6300 daN

9
DIMENSIONS AND LOAD CHART MLT 742 H Turbo LSU Série 3-E2
A 1200 mm
B 2560 mm
C 1142 mm
C1 1245 mm
D 4491 mm
D1 4594 mm
MLT742 D2 3949 mm
50° 60° 62° E 5691 mm
8 F 1870 mm
F1 1870 mm
40°
7
G 455 mm
6,84
G1 440 mm
6
G2 440 mm
I 789 mm
30° J 865 mm
5
K 1260 mm
L 45 mm
4
N 1720 mm
4200Kg
3000Kg
20°
O 125 mm
2500Kg
3
2000Kg
P2 47,5 °
P3 53 °
1500Kg
2
10° R 3475 mm
S 7324 mm
1
T 3380 mm
N°244634
0° U1 2300 mm
0m
-3° 0.5m U2 2550 mm
5 4 3 2 1 0m V 4630 mm
3,93 3,10 2,03 1,25
3,78 2,52 1,50 V1 1250 mm
W 2325 mm
Y 12,3 °
Z 133,5 °
10
DIMENSIONS AND LOAD CHART MT 1033 HL Turbo Série 3-E2
A 1200 mm
B 2810 mm
C 1393 mm
C1 1482 mm
D 4966 mm
D1 5055 mm
D2 4158 mm
E 6166 mm
MT/ MLT1033L F 1846 mm
50° 60° 60.5° F1 1846 mm
G 455 mm
40° 10
9,61 G1 440 mm
9 G2 440 mm
H 10 °
8
H1 10 °
30°
7 I 763 mm
J 865 mm
6
K 1040 mm
5 L 45 mm
3300kg
20° N 1690 mm
2500kg
4
2000kg
O 125 mm
1500kg
1200kg
3 P2 38 °
900kg
550kg
10° P3 53 °
2
600kg
R 3610 mm
1 S 7815 mm
0° T 3565 mm
N°241103
0m
0,5m
U1 2300 mm
-5,5°
-1 U2 2550 mm
7 6 5 4 3 2 1 0m
V 4925 mm
7,06 5,60 4,68 3,29 2,05
6,80 4,08 2,73 1,43 V1 1360 mm
W 2261 mm
Y 11,9 °
Z 113,7 °
11
FILTERS CARTRIDGES AND BELTS
I.C. ENGINE
ALTERNATOR BELT
Part number: 476954
Part number: 605041
Change: 500 H

Change: 500 H*


FUEL PRE-FILTER CARTRIDGE

Part number: 706497
Part number: 226611
Change: 500 H
TRANSMISSION
Part number: 236095
Change: 500 H
HYDRAULIC
FILTER CAP FOR HYDRAULIC OIL TANK DISTRIBUTOR CONTROL HEAD FILTER
Change: 1000 H Change: 1000 H
CAB
Part number: 225052
Part number: 225052
Clean: 50 H
Clean: 500 H
Change: 250 H
12
FILTERS CARTRIDGES AND BELTS
I.C. ENGINE
ALTERNATOR BELT
Part number: 476954
Part number: 605041
Change: 500 H

Change: 500 H*


FUEL PRE-FILTER CARTRIDGE

Part number: 706497
Part number: 226611
Change: 500 H
TRANSMISSION
Part number: 236095
Change: 500 H
HYDRAULIC

Part number: 62415
Change: 1000 H
CAB
Part number: 225052
Part number: 225052
Clean: 50 H
Clean: 500 H
Change: 250 H
13
LUBRICANTS AND FUEL




• DERV to EN590
• BS2869 Class A2
I.C. ENGINE
5 L. 661706
11 Liters MANITOU Oil 20 L. 582357
I.C. ENGINE
API CH4 55 L. 582358
209 L. 582359
2 L. 473076
Cooling liquid
5 L. 470077
(protection - 30°)
20 L. 470078
2 L. 554002
Cooling liquid
5 L. 554003
(protection - 25°)
20 L. 554004
TRANSMISSION
2 L. 499237
MANITOU Oil
20 L. 546330
55 L. 546221
209 L. 546220
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
JIB
400 g. 545996
MANITOU Grease
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
HYDRAULIC
5 L. 545500
209 L. 546109
14
BRAKE
MANITOU Oil
Mineral brake fluid
CAB
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
1 L. 490402
5 L. 486424
FRONT AXLE
5 L. 545976
MANITOU Oil
209 L. 546222
2 L. 499237
MANITOU Oil
20 L. 546330
55 L. 546221
209 L. 546220
400 g. 545996
MANITOU Grease
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
FRONT AXLE OSCILLATION MANITOU Grease
5 Kg. 554974
MT 1033 H L Turbo Série 3-E2 Multipurpose HD NLGI 2
20 Kg. 499233
50 Kg. 489670
REAR AXLE
5 L. 545976
MANITOU Oil
209 L. 546222
2 L. 499237
MANITOU Oil
20 L. 546330
55 L. 546221
209 L. 546220
400 g. 545996
MANITOU Grease
Multipurpose NLGI 2
50 Kg. 499235
400 g. 161589
1 Kg. 554973
MANITOU Grease
20 Kg. 499233
50 Kg. 489670
,CHASSIS
400 g. 161589
1 Kg. 554973
TILTING CORRECTOR MANITOU Grease
5 Kg. 554974
MT 1033 H L Turbo Série 3-E2 Multipurpose HD NLGI 2
20 Kg. 499233
50 Kg. 489670
15
16
GROUP 10
I. C. ENGINE
M
R
547981EN
GROUP 30
AXLE ASSEMBLY
M
R
547983
DISMANTLING : DROP BOX TYPE 357
30-3-10 EN
15 / 05 / 2002
MO357A10
maintenance and repair

INSTRUCTION MANUAL
MANUALE D'ISTRUZIONE E RIPARAZIONE
WARTUNG UND REPARATURANLEITUNG
MANUAL DE MANUTENCION Y REPARACION
MANUAL ENTRETIEN ET REPARATION
DROP BOX TYPE 357

1
Vietata la riproduzione anche parziale di testo ed illustrazioni
Impaginazione: TEMAS s.r.l. - Gallarate (Va)

Stampa: Gennaio 1998 (N.L. 7309)
Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudatied apporvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.
2
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
GB
INTRODUCTION..................................................................................................................................................................................................... 4
MAINTENANCE AND LUBRICANT .......................................................................................................................................................................... 6
CONVERSION TABLES .......................................................................................................................................................................................... 7
TIGHTENING TORQUES ........................................................................................................................................................................................ 7
DIAGRAMS OF REDUCTION UNIT AND EXPLODED VIEWS ................................................................................................................................... 8
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357........................................................................................................................ 10
REMOVAL OF HYDRAULIC GEAR CONTROL....................................................................................................................................................... 12
ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ............................................................................................................................. 28
INSTALLATION OF HYDRAULIC GEAR CONTROL ............................................................................................................................................... 44
INTRODUZIONE .......................................................4 VORAUSSETZUNG .................................................. 4

ITA D
MANUTENZIONE E LUBRIFICANTI...........................6 WARTUNG UND SCHMIERSTOFFE ......................... 6
TABELLE DI CONVERSIONE....................................7 UMRECHNUNGSTABELLEN .................................... 7
COPPIE DI SERRAGGIO .............................................................7 ANZIEHDREHMOMENTE ............................................................ 7
SCHEMI RIDUTTORE ED ESPLOSI .............................................8 SCHEMAS FUÈR UNTERSETZUNGSGETRIEBE
SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO ........10 UND ZUSAMMENSTELLUNGSZEICHNUNGEN ........................... 8
RIMOZIONE COMANDO MARCIA IDRAULICO ...........................12 DIREKT GEFLANSCHTER REDUZIERER 357 ZERLEGEN ......... 10
ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO.....28 HYDRAULISCHER GANGSCHALTUNG ENFERNEN.................. 12
INSTALLAZIONE COMANDO MARCIA IDRAULICO ....................44 DIREKT GEFLANSCHTER REDUZIERER 357 MONTIEREN ....... 28
HYDRAULISCHER GANGSCHALTUNG MONTIEREN ................ 44
PROLOGO ...............................................................4 INTRODUCTION....................................................... 4

ESP MANTENIMIENTO Y LUBRICANTES .........................6 F ENTRETIEN ET LUBRIFIANTS ................................. 6
TABLAS DE CONVERSION.......................................7 TABLEAUX DE CONVERSION.................................. 7
PARES DE TORSION ..................................................................7 COUPLES DE SERRAGE ............................................................ 7
DIAGRAMAS REDUCTOR Y VISTAS PORMENORIZADAS ...........8 TRACES REDUCTEUR ET EXPLOSIFS....................................... 8
DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA ...............10 DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357............... 10
REMOCION MANDO MARCHA HIDRAULICO.............................12 DEPLACEMENT DE LA COMMANDE DE VITESSES
MONTAJE GRUPO REDUCTOR 357 CON BRIDA ......................28 HYDRAULIQUE ........................................................................ 12
MONTAJE MANDO MARCHA HIDRAULICO...............................44 ASSEMBLAGE DU GROUPE REDUCTEUR BRIDE 357 ............. 28
INSTALLATION DE LA COMMANDE DE VITESSES
HYDRAULIQUE ........................................................................ 44
3
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, extractors and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la SPICER CLARK-HURTH.
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of SPICER mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
CLARK-HURTH. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Auszieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
4
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos
Spiele, Vorspannungen und Drehmomente strengstens ein- de las herramientas especificas necesarias para la ejecucioÂn
gehalten werden. de las intervenciones de mantenimiento figuran al final del
manual; los recambios se pueden pedir al fabricante de la
GUÈ LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern maÂquina o directamente al Service Center o a Distribuidores
die Einheiten gehoÈren. Der Einfachheit halber sind die autorizados de SPICER CLARK-HURTH.
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
SPICER CLARK-HURTH bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
fournis par le constructeur du veÂhicule. En deÂcrivant les
El rendimiento y la duracioÂn de los oÂrganos
ESP opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mecaÂnicos depende, ademaÂs que del constante y
enleveÂ du veÂhicule.
correcto mantenimiento, tambieÂn de la interven-
cioÂn inmediata en caso de averõÂas o anomalõÂas. IMPORTANT: Pour faciliter le travail en sauvegardant en
Al proponer este manual, ha sido considerada la suposicioÂn de meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
una revisioÂn general del grupo, pero es el mecaÂnico quien tiene teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
que valorar la necesidad de montar cada uno de los telles que des eÂtais ou banc de support, maillets en plastique
componentes en caso de reparacioÂn. El manual es una guõÂa ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
raÂpida y segura que permite intervenciones precisas por medio Avant de proceÂder au deÂmontage des parties et vidanger
de fotografõÂas y de planos que muestran las distintas fases de l'huile, il vaut mieux nettoyer soigneusement le pont, en
las operaciones. A continuacioÂn figuran todas las informacio- enlevant incrustations et blocs de gras.
nes y advertencias necesarias para ejecutar un montaje
correcto, para las comprobaciones y el montaje de cada uno PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
de los componentes. Para remover el puente diferencial del doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
vehõÂculo hay que consultar los manuales de los fabricantes del approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
vehõÂculo. En la descripcioÂn de las operaciones siguientes se abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
supone que el puente ya ha sido sacado del vahõÂculo. particulier, de toutes les parties en mouvement (paliers,
engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
IMPORTANTE: Para facilitar el trabajo salvaguardando al bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
mismo tiempo las superficies mecanizadas y la seguridad de sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
los operadores, se aconseja que se usen equipos y herra- substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
mientas adecuados como caballetes y bancos de soporte, effectue une reÂvision ou une reÂparation des composants. Au
martillos de plaÂstico o de cobre, palancas adecuadas, moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
extractores y llaves especõÂficas. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
Antes de desmontar las partes y descargar el aceite, es conique, la substitution de l'un de ses engrenages comporte
conveniente que se haga una limpieza minuciosa del puente eÂgalement la substitution de l'autre. En phase de montage, il
sacando las incrustaciones y acumulaciones de grasa. faut respecter scrupuleusement les jeux, les preÂcharges et les
couples prescrits.
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados
tienen que ser limpiados minuciosamente con productos VALIDITE: Le manuel fournit la validiteÂ des groupes sous
adecuados y restaurados o sustituidos en el caso de que forme de matricule. Pour une meilleure interpreÂtation, les
presenten danÄos, desgaste, rajaduras, agarrotamientos, etc. validiteÂs sont indiqueÂes comme:
En particular, comprobar la integridad de todas las partes en
movimiento (cojinetes, engranajes, par coÂnico, ejes) y de = jusqu'aÁ l'immatriculation
estanqueidad (anillos OR, detenedor de aceite) sujetas a
mayores solicitaciones y desgaste. = aÁ partir de l'immatriculation et apreÁs
Se aconseja, de todas formas, que se sustituyan los oÂrganos
de estanqueidad cada vez que se ejecute la revisioÂn o Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
reparacioÂn de los componentes. deÂmontage et d'assemblage sont pareilles dans toutes les
Al volver a montar, los segmentos de compresioÂn tienen que versions.
estar lubricados en los bordes de estanqueidad. En el caso del
par coÂnico, la sustitucioÂn de uno de sus engranajes comporta INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
tambieÂn la sustitucioÂn del otro. Al montar hay que tener en Les dessins des installations speÂcifiques neÂcessaires pour
cuenta escrupulosamente los juegos, las precargas y los pares effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
descriptos. manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
constructeur de la machine ou directement aux Centres de
VALIDEZ: El manual suministra la validez de los grupos en Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ SPICER
forma de matrõÂcula. Para poder tener una interpretacioÂn CLARK-HURTH.
correcta, la validez estaÂ indicada:
= hasta la matrõÂcula
= desde la matrõÂcula en adelante
5
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
D1240009
Oil fill and level plug Oil drain plug
1 2
Tappo carico e livello olio Tappo scarico olio
È leinfu
O È lstandschraube
Èll- und O È leinfu
O È lablaûschraube
Èll- und O
Tapo Â n de relleno y nivel aceite Tapo Â n de vaciado nivel aceite
Bouchon de remplissage et jauge d'huile Bouchon de vidage huile
1 2
3
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
D1240011
Type and model unit Serial number Lubrificant
1 2 3
Tipo e modello gruppo Numero di serie Lubrificante
Type und modell Antriebes Seriennummer Schmieroel
Tipo y modelo unidad Â mero de serie
Nu Lubricante
Â le de ensemble
Type et mode Numero de serie Lubrificant
OPERATION FREQUENCY LUBRICANTS

OPERAZIONE Á
PERIODICITA LUBRIFICANTI
ARBEITSVORGANG ZEITABSTAND SCHMIERSTOFFE
OPERACION FRECUENCIA LUBRICANTES
OPERATION PERIODICITE LUBRIFIANTS
. Check levels: monthly
. Controllo livelli: mensile
. È lstandkontrolle:
O monatlich
. Control niveles: cada mes
. ControÃle niveaux: mensuel
SAE85W90 API GL3
. Oil change: every 1000 hours ]
. Cambio olio: ogni 1000 ore
. È lwechsel:
O alle 1000 Std.
. Cambio aceite: cada 1000 horas
. Vidange huile: toutes les 1000 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de
100 horas de trabajo - Initialement apreÁs 100 heures de travail
6
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
1 Atm%1 bar%105 PA%14.4 PSi

Pa
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS

SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS
TAMAN Ä O TORNILLO
8G/8,8 10k/10,9 12k/10,9
MESURE VIS Nm Nm Nm
M4 2,9 4,1 Ð
M6 10,0 14,0 Ð
M8 25,0 35,0 Ð
M10 49,0 69,0 Ð
M10x1,25 52,0 73,0 88,0
M12 86,0 120,0 Ð
M14 135,0 190,0 Ð
M14x1,5 150,0 210,0 250,0
M16 210,0 295,0 Ð
M18x1,5 325,0 460,0 550,0
A22 550
7
DIAGRAMS OF REDUCTION UNIT AND EXPLODED VIEWS - SCHEMI RIDUTTORE ED ESPLOSI - SCHEMAS FUÈR UNTERSETZUNGSGETRIEBE
UND ZUSAMMENSTELLUNGSZEICHNUNGEN - DIAGRAMAS REDUCTOR Y VISTAS PORMENORIZADAS - TRACES REDUCTEUR ET EXPLOSIFS
DIAGRAM
SCHEMA
SCHEMAS
DIAGRAMAS
TRACES
D1240001
TECHNICAL DATA - CARATTERISTICHE TECNICHE - TECHNISCHE DATEN - CARACTERI-

STICAS TECNICAS - CARACTERISTIQUES TECHNIQUES
A- Connector for hydraulic gear control - Pressure required 15±30 bar
Raccordi comando marce idraulico - Pressione di comando 15±30 bar
Anschluss fuÈr hydraulischer BetaÈtigung der Gangschaltung Schaltdruck 15±30 bar
ConexioÂn mando marcha hydraulico - PresioÂn de mando 15±30 bar
Raccord commande des vitesses hydraulique - Pression de commande 15±30 bar
REDUCTION GEAR
RIDUTTORE
UNTERSETZUNGSGETRIEBE
REDUCTOR
REDUCTEUR
D1240012
] OPTIONAL
8
Ist GEAR
Ië MARCIA
Ië GANG
Ië MARCHA
Ië VITESSE
D1240002
IInd GEAR
IIë MARCIA
IIë GANG
IIë MARCHA
IIë VITESSE
D1240003
9
SYMBOLS - SIMBOLI - SYMBOLS
SIMBOLOS - SYMBOLES
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice
Attenzione, indicazione importante
Achtung, wichtiger Hinweis
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc.
Controler, regler p.e. couples, mesures, pressions ecc.
T=Special tool P=page
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly
Sostituire con ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung)
Colocar el seguro, pegar (mastique lõÂquido)
Mettre la securite, coller (mastic liquide)
Guard against material damage, damage to parts
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
Inserire pressione nel circuito idraulico
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique
To clean
Pulire
Reinigen
Limpiar
Nettoyer
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357- SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
REDUZIERER 357 ZERLEGEN - DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA - DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357
F1240069 F1240070
GB a GB b
Reduction gear directly flanged on the axle with mechanic gear Reduction gear directly flanged on the axle with hydraulic gear
control. control.
F1240071
GB c GB d
Reduction gear directly flanged on the axle with or without
revolution indicator.
GB e GB f
10
Versione afflangiata al ponte con comando marcia Versione afflangiata al ponte con comando marcia
ITA meccanico. ITA idraulico.
Direkt an der Triebachse geflanscht mit mechanischer Direkt an der Triebachse geflanscht mit hydraulischer
D Gangschaltung. D Gangschaltung.
a b
VersioÂn con brida en el puente con mando mecaÂnico VersioÂn con brida en el puente con mando hidraÂulico
ESP de la marcha. ESP de la marcha.
ModeÁle brideÂ au pont aÁ commande de vitesses ModeÁle brideÂ au pont aÁ commande de vitesses
F meÂcanique. F hydraulique.
Versione afflangiata al ponte con o senza rilevatore di

ITA giri. ITA
Direkt an der Triebachse geflanscht mit oder ohne

D Drehzahlmesser. D
c d
VersioÂn con brida en el puente con o sin detector de
ESP revoluciones. ESP
ModeÁle brideÂ pont avec ou sans compteur de tours.

F F
ITA ITA
D D
e f
ESP ESP
F F
11
REMOVAL OF HYDRAULIC GEAR CONTROL - RIMOZIONE COMANDO IDRAULICO - HYDRAULISCHER GANGSCHALTUNG ENFERNEN -
REMOCION MANDO MARCHA HIDRAULICO - DEPLACEMENT DE LA COMMANDE DE VITESSES HYDRAULIQUE
F1240072 F1240073
GB a GB b
Remove the gear control rod. Pull out the control rod.
F1240074 F1240075
GB c GB d
Remove screws on the gear control cylinder. Remove the gear control cylinder.
F1240076 F1240077
GB e GB f
Pull out the gear control cylinder. Re-assembly arrangement of gear control cylinder parts.
Pay attention to the position of the O-rings. Remove the protection
plate.
12
Rimuovere l'asta di comando marce. Estrarre l'asta comando.
ITA ITA
Gangschalterhebel abnehmen. Hebel herausziehen.

D D
a b
Remover la varilla de mando de las marchas. Extraer la varilla de mando.
ESP ESP
Enlever la tringle de commande de vitesses. Extraire la tringle de commande.

F F
Rimuovere le viti del cilindro comando marce. Rimuovere il cilindro comando marce.
ITA ITA
Die Schrauben vom Zylinder des Gangschalters Zylinder des Gangschalters abnehmen.
D abnehmen. D
c d
Remover los tornillos del cilindro de mando de las Remover el cilindro de mando de las marchas.
ESP marchas. ESP
Enlever les vis du cylindre de commande de vitesses. Enlever le cylindre de commande de vitesses.
F F
Estrarre il cilindro comando marce. Ordine di rimontaggio dei particolari del cilindro di
ITA Prestare attenzione alla posizione degli anelli OR. ITA comando marce.
Rimuovere la lamiera di protezione.
Zylinder des Gangschalters herausziehen. Reihenfolge zur Montage der Einzelteile des Gangs-
D Auf die Position der O-Ringe achten. Schutzblech D chalterzylinders.
abnehmen.
e f
Extraer le cilindro de mando de las marchas. Orden para volver a montar las piezas del cilindro de
ESP Tener cuidado con la posicioÂn de los anillos OR. ESP mando de las marchas.
Remover la placa de proteccioÂn.
Extraire le cylindre de commande de vitesses Placer les pieÁces en ordre en vue du remontage du
F Faire attention au positionnement des bagues OR F cylindre de commande de vitesses.
Enlever la toÃle de protection.
13
F1240078 F1240079
GB a GB b
Remove fastening screws from the reduction unit. Disjoin the entire reduction unit from the axle and place it on a
bench.
F1240080 F1240081
GB c GB d
Remove the sealing cover with the relative washer or the revolution Remove gear-in position switch, O-ring and washer.
indicator.
F1240082 F1240083
GB e GB f
Remove screw, spring, together with gear-and-neutral position Remove screw, spring and neutral position ball (hydraulic version).
spindle (mechanical version).
14
Rimuovere le viti di fissaggio del riduttore. Staccare il riduttore completo dal ponte e posizionarlo
ITA ITA su un banco.
Reduziererbefestigungsschrauben abschrauben. Den gesamten Reduzierer von der Triebachse neh-

D D men und einen Tisch legen.
a b
Remover los tornillos de fijacioÂn de reductor. Desprender el reductor completo del puente y posi-
ESP ESP cionarlo en un banco.
Enlever les vis de fixation du reÂducteur. DeÂtacher le reÂducteur tout entier du pont et le mettre
F F sur le banc.
Rimuovere il tappo di chiusura con rosetta oppure il Rimuovere l'interruttore di posizione marcia inserita
ITA rilevatore di giri. ITA con anello OR e rosetta.
Stopfen mit Unterlegscheibe oder Drehzahlmesser Schalter fuÈr die Position der Gangschaltung mit O-
D entfernen. D Ring und Unterlegscheibe entfernen.
c d
Remover el tapoÂn de cierre con la roseta o bien el Remover el interruptor de posicioÂn de marcha em-
ESP detector de revoluciones. ESP bragada con el anillo OR y la roseta.
Enlever le bouchon de verrouillage aÁ rondelle ou bien Enlever l'interrupteur de la position vitesses incorporeÂ
F le compteur de tours. F avec la bague OR et la rondelle.
Rimuovere la vite, la molla ed il puntalino di posizione Rimuovere la vite, la molla e la sfera di posizone folle
ITA marcia e folle (versione meccanica). ITA (versione idraulica).
Schraube, Feder und Stift fuÈr die Position der Gangs- Schraube, Feder und Kugel fuÈr die Position des
D chaltung und des Leerlaufs entfernen (mechanische D Leerlaufs entfernen (hydraulische AusfuÈhrung).
AusfuÈhrung).
e f
Remover el tornillo, el muelle y el pasador de posicioÂn Remover el tornillo, el muelle y la bola de posicioÂn de
ESP de marcha y punto neutro (versioÂn mecaÂnica). ESP punto neutro (versioÂn hidraÂulica).
Enlever la vis, le ressort et la buteÂe de position Enlever la vis, le ressort et la spheÁre de position point
F vitesses et point mort (modeÁle meÂcanique). F mort (modeÁle hydraulique).
15
F1240084 F1240085
GB a GB b
Remove screws from the motion input cover. Disjoin the motion entrance cover.
F1240086 F1240087
GB c GB d
Remove the nut from the flange. Remove the O-ring and pull out the flange.
F1240088
GB e GB f
Remove screws from the cover.
16
Rimuovere le viti del coperchio di entrata del moto. Staccare il coperchio di entrata del moto.
ITA ITA
Die Deckelschrauben am Anfang der Bewegung Deckel am Eingang des Bewegung abnehmen.
D abschrauben. D
a b
Remover los tornillos de la tapa de entrada del Desprender la tapa de entrada del movimiento.
ESP movimiento. ESP
Enlever les vis du couvercle d'entreÂe du mouvement. DeÂcrocher le couvercle d'entreÂe du mouvement.
F F
Rimuovere il dado della flangia. Asportare l'anello OR ed estrarre la flangia.

ITA ITA
Flanschmutter abschrauben. O-Ring abnehmen und Flansch herausziehen.

D D
c d
Remover la tuerca de la brida. Quitar el anillo OR y extraer la brida.
ESP ESP
Enlever l'eÂcrou de la flasque. Enlever la bague OR et extraire la flasque.

F F
Rimuovere le viti del coperchio.

ITA ITA
Deckelschrauben abschrauben.
D D
e f
Remover los tornillos de la tapa.
ESP ESP
Enlever les vis du couvercle.

F F
17
F1240089 F1240090
GB a GB b
Disjoin the cover. Remove the cover by fixing the distance washers onto the cover
itself.
Caution: the niche must be facing upwards.
F1240091 F1240092
GB c GB d
Remove screws. Remove the cover.
Take care not to damage planes.
F1240093
GB e GB f
Take away the cover.
Pay attention to the position of the pins.
18
Staccare il coperchio. Rimuovere il coperchio fissando gli spessori allo
ITA ITA stesso.
Attenzione: nicchia rivolta verso l'alto.
Deckel abnehmen. Deckel abnehmen und DistanzstuÈcke am Deckel

D D befestigen.
Achtung: die Nische ist nach oben gerichtet.
a b
Desprender la tapa. Remover la tapa fijando los espesores en la misma.
ESP ESP Cuidado: el hueco tiene que estar dirigido hacia
arriba.
DeÂcrocher le couvercle. Enlever le couvercle en fixant les cales aÁ ce dernier.

F F Attention: au logement tourneÂ vers le haut.
Rimuovere le viti. Rimuovere il coperchio.

ITA ITA Prestare attenzione per non danneggiare i piani.
Schrauben abschrauben. Deckel abnehmen.

D D Darauf achten, die FlaÈchen nicht zu beschaÈdigen.
c d
Remover los tornillos. Remover la tapa.
ESP ESP Poner mucho cuidado a fin de no danÄar las superfi-
cies.
Enlever les vis. Enlever le couvercle.

F F Faire attention aÁ ne pas endommager les surfaces.
Togliere il coperchio.
ITA Prestare attenzione alla posizione delle spine. ITA
Deckel abnehmen.
D Auf die Position der Stifte achten. D
e f
Sacar la tapa.
ESP Tener mucho cuidado con la posicioÂn de las clavijas. ESP
Enlever le couvercle.
F Faire attention aÁ la position des broches. F
19
F1240094 F1240095
GB a GB b
Pull out gear, needle bearings and distance piece form the box. Remove the bearing if it needs replacing.
F1240096 F1240097
GB c GB d
Re-introduce the bearing into the box. Remove the oil shield plate only if necessary.
Caution: the oil inlet must face upwards.
F1240098 F1240099
GB e GB f
Re-introduce the oil shield plate with oil inlet facing upwards. Fit the oil shield plate into position 5±5.5 mm from box plane.
Apply LOCTITE 510 on the outside.
20
Estrarre dalla scatola l'ingranaggio, i cuscinetti a Rimuovere il cuscinetto se eÁ da sostituire.
ITA rullini ed il distanziale. ITA
Aus der Schachtel das Zahnrad, die Kugellager und Lager herausnehmen, wenn es ausgewechselt wer-
D das DistanzstuÈck nehmen. D den soll.
a b
Extraer de la caja el engranaje, los cojinetes de agujas Remover el cojinete si hay que sustituirlo.
ESP y el separador. ESP
Extraire la boõÃte d'engrenage, les paliers aÁ rouleaux et Enlever le palier s'il est aÁ remplacer.
F l'entretoise. F
Reinserire il cuscinetto nella scatola. Rimuovere la lamiera paraolio solo se necessario.

ITA ITA Attenzione: l'entrata dell'olio deve essere rivolta verso
l'alto.
Lager in die Schachtel einsetzen. È labdichtung nur abnehmen, wenn es noÈtig sein
O
D D sollte.
È leingang muû nach oben gerichtet sein.
Achtung: der O
c d
Volver a colocar el cojinete en la caja. Remover el sello de aceite si fuera necesario.
ESP ESP Cuidado: la entrada del aceite tiene que estar dirigida
hacia arriba.
ReÂinseÂrer le palier dans la boõÃte. Enlever la toÃle pare-huile seulement si besoin.

F F Attention: l'orifice de huile doit eÃtre tourneÂe vers le
haut.
Reinserire lamiera paraolio con l'entrata dell'olio verso Posizionare la lamiera paraolio a 5v5,5 mm dal piano
ITA l'alto. ITA scatola.
Spalmare sull'esterno LOCTITE 510.
È labdichtung mit dem Eingang nach oben wieder

O È labdichtung in einem Abstand von 5v5,5 mm von
O
D einsetzen. D der SchachtelflaÈche einsetzen.
Auûen mit LOCTITE 510 schmieren.
e f
Volver a colocar el sello de aceite con la entrada del Posicionar el sello de aceite a 5v5,5 mm de la
ESP aceite hacia arriba. ESP superficie de la caja.
Engrasar por fuera con LOCTITE 510.
ReÂinseÂrer la toÃle pare-huile avec l'orifice de l'huile Placer la toÃle pare-huile aÁ 5v5,5 mm de la surface de
F tourneÂe vers le haut. F la boõÃte.
Enduire du LOCTITE 510 aÁ l'exteÂrieur.
21
F1240100 F1240101
GB a GB b
Remove the check screws from the flow regulator plate. Remove the plate and pull out coupling and fork at the same time.
F1240102 F1240103
GB c GB d
Check: sliding blocks, pin, and sliding coupling. Remove the lower shaft.
Replace if worn.
F1240104
GB e GB f
Remove the entire shaft and the flow regulator plate.
22
Rimuovere le viti di ritegno lamiera frangiflusso. Asportare la lamiera ed estrarre contemporaneamente
ITA ITA il manicotto e la forcella.
Befestigungsschrauben des Strahlreglers abschrau- Strahlregler abnehmen und gleichzeitig HuÈlse und
D ben. D Gabel herausziehen.
a b
Remover los tornillos de retencioÂn de la placa Sacar la placa y extraer contemporaÂneamente el
ESP deflectora. ESP manguito y la horquilla.
Enlever les vis de fixation de la toÃle brise-jet. Enlever la toÃle et extraire, en meÃme temps, le
F F manchon et la fourchette.
Verificare: pattini, spina e manicotto scorrevole. Rimuovere l'albero di uscita.

ITA Sostituirli se sono usurati. ITA
Zu kontrollieren: Gleitschuhe, Stift und GleithuÈlse. Ausgangswelle abnehmen.

D Wenn verschleiût, auswechseln. D
c d
Comprobar: patines, clavija y manguito corredizo. Remover el eje de salida.
ESP Sustituirlos si estaÂn gastados. ESP
VeÂrifier: pattes, broches et manchon coulissant. DeÂplacer l'arbre de sortie.

F Remplacer s'ils sont useÂs. F
Asportare l'albero completo e la lamiera frangiflusso.

ITA ITA
Die ganze Welle und den Strahlregler abnehmen.

D D
e f
Sacar el eje completo y la placa deflectora.
ESP ESP
Enlever l'arbre au complet ainsi que la toÃle brise-jet.

F F
23
F1240105 F1240106
GB a GB b
Disassembly of the entire lower shaft. Progressive arrangement of parts fitted onto the lower shaft.
F1240107 F1240108
GB c GB d
Assembly of lower shaft. Removal of upper shaft.
(In case of replacement, the shaft is supplied already assembled).
F1240109 F1240110
GB e GB f
Pull out the sealing ring. Re-insert a new sealing ring.
24
Smontaggio dell'albero di uscita completo. Disposizione progressiva dei particolari montati su
ITA ITA albero di uscita.
Ganze Ausgangswelle abmontieren. Reihenfolge der auf der Ausgangswelle montierten

D D Einzelteile.
a b
Desmontaje del eje de salida completo. DisposicioÂn progresiva de las piezas montadas en el
ESP ESP eje de salida.
DeÂmontage complet de l'arbre de sortie. Mise en place progressive des pieÁces monteÂes sur
F F l'arbre de sortie.
Assemblaggio dell'albero di uscita. Rimuovere l'albero di entrata.

ITA ITA (Nel caso di sostituzione, viene fornito premontato).
Zusammenbau der Ausgangswelle. Eingangswelle entfernen.

D D (Bei Ersatz, wird sie schon montiert geliefert).
c d
Montaje del eje de salida. Remover el eje de entrada.
ESP ESP (En el caso de sustitucioÂn, se entrega ya premontado).
Assemblage de l'arbre de sortie. DeÂplacer l'arbre d'entreÂe.

F F (En cas de substitution, il est fourni preÂmonteÂ).
Estrarre l'anello di tenuta. Reinserire il nuovo anello di tenuta.

ITA ITA
Dichtungsring herausziehen. Den neuen Dichtungsring einsetzen.

D D
e f
Extraer el segmento de compresioÂn. Volver a insertar el segmento de compresioÂn.
ESP ESP
Extraire la bague d'eÂtancheÂiteÂ. Introduire la bague d'eÂtancheÂiteÂ neuve.

F F
25
F1240111 F1240112
GB a GB b
Pull out the sealing ring of the cover. Re-insert a new sealing ring.
F1240113 F1240114
GB c GB d
Pull out the sealing ring from the motion input cover. Remove the bearing from the cover of the reduction unit.
GB e GB f
26
Estrarre l'anello di tenuta del coperchio. Reinserire il nuovo anello di tenuta.
ITA ITA
Dichtungsring des Deckels herausziehen. Den neuen Dichtungsring einsetzen.

D D
a b
Extraer el segmento de compresioÂn de la tapa. Insertar el nuevo segmento de compresioÂn.
ESP ESP
Extraire la bague d'eÂtancheÂiteÂ du couvercle. Introduire la bague d'eÂtancheÂiteÂ neuve.

F F
Estrarre l'anello di tenuta dal coperchio di ingresso del Rimuovere il cuscinetto dal coperchio riduttore.
ITA moto. ITA
Dichtungsring am Anfang der Bewegung herauszie- Lager des Reduziererdeckels entfernen.

D hen. D
c d
Extraer el segmento de compresioÂn de la tapa de Remover el cojinete de la tapa del reductor.
ESP entrada del movimiento. ESP
Extraire la bague d'eÂtancheÂiteÂ du couvercle d'entreÂe Enlever le palier du couvercle du reÂducteur.

F du mouvement. F
ITA ITA
D D
e f
ESP ESP
F F
27
ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 - ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
REDUZIERER 357 MONTIEREN - MONTAJE GRUPO REDUCTOR 357 CON BRIDA - ASSEMBLAGE DU GROUPE REDUCTEUR BRIDE 357
F1240115 F1240116
GB a GB b
Re-fit the bearing in the cover of the reduction unit using ordinary Re-insert the new sealing ring in the motion input cover.
tools.
F1240117 F1240118
GB c GB d
Re-assemble the cover, spreading LOCTITE 510 on planes and Tighten screws using a torque wrench setting of 49±51 Nm.
screws.
F1240119
GB e GB f
Lubricate the lip of the sealing ring with grease.
28
Rimontare il cuscinetto nel coperchio riduttore con i Reinserire il nuovo anello di tenuta coperchio di
ITA normali attrezzi. ITA ingresso del moto.
Lager in den Reduziererdeckel mit gewoÈhnlichen Den neuen Dichtungsring in den Deckel am Eingang
D Werkzeugen montieren. D der Bewegung montieren.
a b
Volver a montar el cojinete en la tapa del reductor con Volver a insertar el nuevo segmento de compresioÂn en
ESP las herramientas normales. ESP la tapa de entrada del movimiento.
Remonter le palier du couvercle reÂducteur aÁ l'aide Introduire la bague d'eÂtancheÂiteÂ neuve dans le
F d'outils habituels. F couvercle d'entreÂe du mouvement.
Rimontare il coperchio spalmando sui piani e sulle viti Serrare le viti con una coppia di serraggio di
ITA LOCTITE 510. ITA 49v51 Nm.
DeckelflaÈchen und -schrauben mit LOCTITE 510 Schrauben mit einem Anziehdrehmoment zu
D schmieren und montieren. D 49v51 Nm anziehen.
c d
Volver a montar la tapa engrasando las superficies y Apretar los tornillos a un par de torsioÂn de di
ESP los tornillos con LOCTITE 510. ESP 49v51 Nm.
Remonter le couvercle en eÂtalant du LOCTITE 510 sur Serrer les vis aÁ un couple de serrage de
F les surfaces et sur les vis. F 49v51 Nm.
Lubrificare con grasso il labbro dell'anello di tenuta.

ITA ITA
Dichtlippe mit Fett schmieren.

D D
e f
Lubricar con grasa el labio del segmento de compre-
ESP sioÂn. ESP
Lubrifier avec du gras la leÁvre de la bague d'eÂtan-

F cheÂiteÂ. F
29
F1240120 F1240104
GB a GB b
Re-assemble the motion upper shaft. Re-assemble the full lower shaft and the flow regulator plate.
F1240121 F1240122
GB c GB d
Position the shaft so that the bearing juts out approximately 5 mm Temporarily re-assemble the cover with screws.
from the cover of the reduction unit. (Be sure that the niche faces upwards).
F1240101 F1240100
GB e GB f
Simultaneously insert: fork and sliding blocks, coupling and flow Re-insert screws and tighten.
regulator plate.
30
Rimontare l'albero di entrata del moto. Rimontare l'albero uscita completo e la lamiera
ITA ITA frangiflusso.
Welle am Eingang der Bewegung montieren. Ganze Ausgangswelle und Strahlregler montieren.
D D
a b
Volver a montar el eje de entrada del movimiento. Volver a montar el eje de salida completo y la placa
ESP ESP deflectora.
Remonter l'arbre d'entreÂe du mouvement. Remonter l'arbre de sortie tout entier et la toÃle brise-
F F jet.
Posizionare l'albero in modo che il cuscinetto sporga Rimontare provvisoriamente il coperchio con le viti.
ITA dal coperchio riduttore circa 5 mm. ITA (Attenzione alla nicchia che deve essere rivolta verso
l'alto).
Die Welle so positionieren, daû das Lager vom VoruÈ bergehend den Deckel mit den Schrauben
D Reduziererdeckel ca. 5 mm herausragt. D montieren.
(Achtung, die Nische muû nach oben gerichtet sein).
c d
Posicionar el eje de manera que el cojinete sobresalga Volver a montar provisionalmente la tapa con los
ESP de la tapa del reductor en unos 5 mm aproximada- ESP tornillos. (Cuidado con el hueco que tiene que estar
mente. dirigido hacia arriba).
Positionner l'arbre de telle sorte que le palier saillisse Remonter provisoirement le couvercle avec les vis.
F du couvercle du reÂducteur d'environ 5 mm. F (Attention le logement doit eÃtre tourneÂ vers le haut).
Reinserire contemporaneamente: la forcella con patti- Reinserire le viti ed avvitarle.

ITA ni, il manicotto e la lamiera frangiflusso. ITA
Gleichzeitig Gabel mit Gleitschuh, HuÈlse und Strahl- Schrauben anbringen und festschrauben.
D regler montieren. D
e f
Volver a insertar contemporaÂneamente la horquilla Volver a introducir los tornillos y atornillarlos.
ESP con los patines, el manguito y la placa deflectora. ESP
ReÂinseÂrer en meÃme temps: la fourchette avec les Introduire les vis et visser.
F pattes, le manchon et la toÃle brise-jet. F
31
F1240123 F1240124
GB a GB b
Tighten screws using a torque wrench setting of 25±26 Nm. Re-assemble needle bearings, gear and distance piece.
F1240125 F1240126
GB c GB d
Check the insertion of pins. Spread LOCTITE 510 on the surface and assemble the cover.
F1240127
GB e GB f
Fasten the cover.
32
Serrare le viti con una coppia di serraggio di Rimontare i cuscinetti a rullini, l'ingranaggio ed il
ITA 25v26 Nm. ITA distanziale.
Schrauben mit einem Anziehdrehmoment zu Kugellager, Zahnrad und DistanzstuÈck montieren.

D 25v26 Nm anziehen. D
a b
Apretar los tornillos a un par de torsioÂn de Volver a montar los cojinetes de agujas, el engranaje y
ESP 25v26 Nm. ESP el separador.
Serrer les vis aÁ un couple de serrage de Remonter les paliers aÁ rouleaux, l'engrenage et
F 25v26 Nm. F l'entretoise.
Verificare l'inserimento delle spine. Spalmare la superficie con LOCTITE 510 e montare il
ITA ITA coperchio.
Einsatz der Stifte kontrollieren. FlaÈche mit LOCTITE 510 schmieren und Deckel
D D montieren.
c d
Comprobar la insercioÂn de las clavijas. Engrasar la superficie con LOCTITE 510 y montar la
ESP ESP tapa.
VeÂrifier l'introduction des broches. Enduire la surface avec du LOCTITE 510 et monter le
F F couvercle.
Mandare il coperchio in battuta.

ITA ITA
Den Deckel zum Anschlag bringen.

D D
e f
Llevar la tapa a tope.
ESP ESP
Lancer le couvercle buteÂe.

F F
33
F1240128 F1240082
GB a GB b
Tighten screws using a torque wrench setting of 49±51 Nm. Grease components and re-introduce spindle, spring and screw
Caution: tighten using the crossed method. (mechanical version).
Tighten using a max. torque wrench setting of 80±100 Nm.
F1240083 F1240081
GB c GB d
Grease components and re-introduce ball, spring and screw Fix the gear-in position switch with washer and O-ring.
(hydraulic version). Tighten with torque wrench setting of max. 54.2 Nm.
Tighten using a max. torque wrench setting of 80±100 Nm.
F1240080
GB e GB f
Assemble the sealing cover with washer and revolution indicator.
Tighten using a torque wrench setting of max. 25 Nm.
34
Serrare le viti con una coppia di serraggio di Ingrassare i componenti e reinserire il puntalino, la
ITA 49v51 Nm. ITA molla, la vite (versione meccanica). Serrare con una
Attenzione: serrare con il metodo incrociato. coppia di serraggio max. di 80v100 Nm.
Schrauben mit einem Anziehdrehmoment zu Einzelteile schmieren und Stift, Feder und Schraube
D 49v51 Nm anziehen. D einsetzen (mechanische AusfuÈhrung). Mit einem An-
Achtung: Schrauben abwechselnd im Kreuz anziehen. ziehdrehmoment zu max. 80v100 Nm anziehen.
a b
Apretar los tornillos a un par de torsioÂn de Engrasar los componentes y volver a insertar el
ESP 49v51 Nm. ESP pasador, el muelle, el tornillo (versioÂn mecaÂnica).
Cuidado: apretar con el meÂtodo cruzado. Apretar a un par de torsioÂn maÂx. dei 80v100 Nm.
Serrer les vis aÁ un couple de serrage de Graisser les composants et reÂinseÂrer la buteÂe, le
F 49v51 Nm. F ressort, la vis (modeÁle meÂcanique).
Attention: serrer avec la meÂthode croiseÂe. Serrer aÁ un couple de serrage max. de 80(100 Nm.
Ingrassare i componenti e reinserire la sfera, la molla e Montare l'interruttore di posizione marcia inserita con
ITA la vite (versione idraulica). ITA rosetta e anello OR.
Serrare con una coppia max. di 80v100 Nm. Serrare con una coppia di serraggio max. di 54,2 Nm.
Einzelteile schmieren und Kugel, Feder und Schraube Schalter fuÈr die Position der Gangschaltung mit
D einsetzen (hydraulische AusfuÈhrung). Mit einem An- D Unterlegscheibe und O-Ring montieren. Mit einem
ziehdrehmoment zu 80v100 Nm anziehen. Anziehdrehmoment zu max. 54,2 Nm anziehen.
c d
Engrasar los componentes y volver a colocar la bola, Montar el interruptor de posicioÂn marcha embragada
ESP el muelle y el tornillos (versioÂn hidraÂulica). ESP con roseta y anillo OR.
Apretar a un par maÂx. dei 80v100 Nm. Apretar a un par de torsioÂn maÂx. de 54,2 Nm.
Graisser les composants et reÂinseÂrer la spheÁre, le Monter l'interrupteur de position de vitesses incorporeÂ
F ressort et la vis (modeÁle hydraulique). F avec la rondelle et la bague OR.
Serrer aÁ un couple max. de 80v100 Nm. Serrer aÁ un couple de serrage max. de 54,2 Nm.
Montare tappo di chiusura con rosetta e rilevatore di

ITA giri. Serrare con una coppia max. di 25 Nm. ITA
Stopfen mit Unterlegscheibe und Drehzahlmesser

D montieren. Mit einem Anziehdrehmoment zu max. 25 D
Nm anziehen.
e f
Montar el tapoÂn de cierre con la roseta y el detector de
ESP revoluciones. Apretar a un par maÂx. de 25 Nm. ESP
Monter le bouchon de verrouilllage accompagneÂ de la

F rondelle et du compteur de tours. Serrer aÁ un couple F
max. de 25 Nm.
35
F1240129 F1240130
GB a GB b
Re-fit the reduction unit onto the axle by spreading LOCTITE 510 Fasten the support planes (turn flange to assist assembly).
on the planes.
F1240131 F1240132
GB c GB d
Insert screws by applying LOCTITE 510. Screw down by placing the reduction unit in a vertical position in
relation to the axis.
F1240133 F1240134
GB e GB f
Tighten screws using a torque wrench setting of 49±51 Nm. Extract screws and remove the temporarily assembled cover.
36
Rimontare il riduttore sul ponte spalmando i piani con Mandare in battuta i piani di appoggio (ruotare la
ITA LOCTITE 510. ITA flangia per facilitare il montaggio).
Reduzierer auf die Triebachse montieren; zuvor die AuflageflaÈchen bis zum Anschlag bringen (Flansch
D FlaÈchen mit LOCTITE 510 schmieren. D drehen um die Montage zu erleichtern).
a b
Volver a montar el reductor en el puente engrasando Llevar a tope las superficies de apoyo (girar la brida
ESP las superficies con LOCTITE 510. ESP para facilitar el montaje).
Remonter le reÂducteur au pont en eÂtalant sur les Lancer les surfaces d'appui en buteÂe (tourner la
F surfaces du LOCTITE 510. F flasque pour faciliter le montage).
Inserire le viti spalmandole con LOCTITE 510. Avvitare le viti posizionando il riduttore in modo
ITA ITA verticale rispetto l'asse.
Schrauben mit LOCTITE 510 schmieren und ein- Schrauben festschrauben; dabei den Reduzierer
D setzen. D senkrecht zur Achse halten.
c d
Insertar los tornillos engrasaÂndolos con LOCTITE 510. Atornillar los tornillos posicionando el reductor de
ESP ESP manera vertical con respecto al eje.
Introduire les vis en les enduisant d'abord de Visser les vis en placËant le reÂducteur verticalement par
F LOCTITE 510. F rapport aÁ l'axe.
Serrare le viti con una coppia di serraggio di Asportare le viti e rimuovere il coperchio montato
ITA 49v51 Nm. ITA provvisoriamente
Schrauben mit einem Anziehdrehmoment zu Schrauben abschrauben und voruÈbergehend montier-

D 49v51 Nm anziehen. D ter Deckel abnehmen.
e f
Apretar los tornillos a un par de torsioÂn de Sacar los tornillos y remover la tapa montada
ESP 49v51 Nm. ESP provisionalmente.
Serrer les vis aÁ un couple de serrage de Enlever les vis et enlever le couvercle provisoirement
F 49v51 Nm. F monteÂ.
37
F1240135 F1240136
GB a GB b
Fasten the bearing by using a standard tool. Measure dimension "A" between the bearing and the box plane
using an ordinary depth gauge (if parts are not replaced, use
disassembled distance washers).
S
F1240137 F1240138
GB c GB d
Measure dimension "B" on the cover, between the bearing plane Apply LOCTITE 510 on the surface, lubricate the sealing ring,
and bearing support. Calculate the dimension of the distance insert the distance washers and re-assemble the cover with niche
washers required: facing upwards.
S=Dimension B Ð Dimension A
Es: B=5.2±A=4.6 mm ± Backlash 0.2±0.3=Distance washer
required=0.4±0.3.
F1240139
GB e GB f
Fit screws after applying LOCTITE 510.
38
Mandare in battuta il cuscinetto utilizzando un Rilevare la quota "A" fra cuscinetto e piano scatola
ITA normale attrezzo. ITA usando un normale calibro di profonditaÁ.
(Se non vengono sostituiti pezzi, utilizzare gli spessori
smontati).
Das Lager bis zum Anschlag bringen; dazu ein Maû "A" zwischen Lager und SchachtelflaÈche mit
D gewoÈhnliches Werkzeug verwenden. D einem gewoÈhnlichen Kaliber messen (wenn keine
Teile ausgewechselt werden, die abmontierten Di-
stanzstuÈcke verwenden).
a b
Llevar a tope el cojinete utilizando una herramienta Registrar la cota "A" entre el cojinete y la superficie de
ESP normal. ESP la caja utilizando un normal calibre de profundidad.
(Si no se sustituyen las piezas, utilizar los espesores
desmontados).
Lancer en buteÂe le palier aÁ l'aide d'un outil normal. Relever la cote "A" entre palier et surface de la boõÃte aÁ
F F l'aide d'un calibre de profondeur normal (S'il n'y a pas
de pieÁces aÁ remplacer, utiliser les cales deÂmonteÂes).
Rilevare la quota "B" sul coperchio fra piano e Spalmare la superficie con LOCTITE 510, lubrificare
ITA appoggio cuscinetto. Calcolare gli spessori da inserire ITA l'anello di tenuta, inserire gli spessori e rimontare il
S=Quota B±Quota A coperchio con la nicchia rivolta verso l'alto.
Es: B=5,2±A=4,6 mm ± Gioco 0,2v0,3= Spessore da inseri-
re=0,4v0,3
Maû "B" am Deckel zwischen FlaÈche und Auflage- FlaÈche mit LOCTITE 510 schmieren; Dichtungsring
D flaÈche des Lagers messen. Die einzulegenden Di- D schmieren; DistanzstuÈcke einsetzen und Deckel mit
stanzstuÈcke ausrechnen. S=Maû B±Maû A Nische nach oben gerichtet, montieren.
Bsp: B=5,2±A=4,6 mm ± Spiel 0,2v0,3=einzusetzende Distanz-
c stuÈcke=0,4v0,3 d
Registrar la cota "B" en la tapa entre la superficie y el Engrasar la superficie con LOCTITE 510, lubricar el
ESP soporte del cojinete. Calcular los espesores que hay ESP segmento de compresioÂn, insertar los espesores y
que insertar S = Cota B±Cota A volver a montar la tapa con el hueco dirigido hacia
Es: B=5,2±A=4,6 mm ± Juego 0,2v0,3= Espesor a inser- arriba.
tar=0,4v0,3
Relever la cote "B" sur le couvercle entre surface et Enduire la surface de LOCTITE 510, lubrifier la bague
F support palier. Calculer le nombre de cales aÁ F d'eÂtancheÂiteÂ, introduire les cales et remonter ensuite
introduire S=Cote B±Cote A le couvercle avec le logement tourneÂ vers le haut.
Exp: B=5,2±A=4,6 mm ± Jeu 0,2v0,3=Cales aÁ introduire
=0,4v0,3
Inseire le viti dopo everle spalmate con

ITA LOCTITE 510. ITA
Schrauben einsetzen; zuvor mit LOCTITE 510

D schmieren. D
e f
Introducir los tornillos despueÂs de engrasarlos con
ESP LOCTITE 510. ESP
Introduire les vis apreÁs les avoir enduites de

F LOCTITE 510. F
39
F1240140 F1240141
GB a GB b
Tighten screws using a torque wrench setting of 49±51 Nm. Assemble flange, O-ring and nut using LOCTITE 242.
F1240142 F1240143
GB c GB d
Screw down the nut of the flange. Tighten the nut using a torque wrench setting of 260±280 Nm.
F1240144 F1240069
GB e GB f
Re-fix the protection plate after applying LOCTITE 510. Complete flanged reduction gear 357 with mechanical gear control.
40
Serrare le viti con una coppia di serraggio di Montare la flangia, l'anello OR e il dado con
ITA 49v51 Nm. ITA LOCTITE 242.
Schrauben mit einem Anziehdrehmoment zu Flansch, O-Ring und Mutter mit LOCTITE 242
D 49v51 Nm anziehen. D schmieren und montieren.
a b
Apretar los tornillos a un par de torsioÂn de Montar la brida, el anillo OR y la tuerca con
ESP 49v51 Nm. ESP LOCTITE 242.
Serrer les vis aÁ un couple de serrage de Monter la flasque, la bague OR et l'eÂcrou enduit de
F 49v51 Nm. F LOCTITE 242.
Avvitare il dado della flangia. Serrare il dado con una coppia di serraggio di
ITA ITA 260v280 Nm.
Flanschmutter festschrauben. Mutter mit einem Anziehdrehmoment zu

D D 260v280 Nm anziehen.
c d
Atornillar la tuerca de la brida. Apretar la tuerca a un par de torsioÂn de
ESP ESP 260v280 Nm.
Visser l'eÂcrou de la flasque. Serrer l'eÂcrou aÁ un couple de serrage de

F F 260v280 Nm.
Rimontare lamiera di protezione dopo everla spalmata Gruppo riduttore 357 afflangiato con comando marcia
ITA con LOCTITE 510. ITA meccanico completo.
Schutzblech mit LOCTITE 510 schmieren und mon- Ganzes direkt geflanschter Reduzierer 357 mit me-
D tieren. D chanischer Gangschaltung.
e f
Volver a montar la placa de proteccioÂn despueÂs de Grupo reductor 357 con brida con mando de marcha
ESP engrasarla con LOCTITE 510. ESP mecaÂnico completo.
Remonter la toÃle de protection apreÁs l'avoir enduite de Groupe reÂducteur brideÂ 357 aÁ commande de vitesses
F LOCTITE 510. F meÂcanique complet.
41
F1240145 F1240144
GB a GB b
Re-assemble all the parts of the gear control cylinder, according to Re-fix the protection plate after applying LOCTITE 510 on it.
their arrangement.
F1240146 F1240147
GB c GB d
Re-fit the gear control cylinder into place with its O-ring. Re-fit screws and screw down.
F1240148
GB e GB f
Re-introduce the gear control rod after applying LOCTITE 242 on it.
42
Rimontare tutti i particolari del cilindro comando Rimontare lamiera di protezione dopo averla spalmata
ITA marcia come disposti in ordine. ITA con LOCTITE 510.
Alle Einzelteile des Zylinders des Gangschalters der Schutzblech mit LOCTITE 510 schmieren und mon-
D Reihenfolge nach montieren. D tieren.
a b
Volver a montar todas las piezas del cilindro mando Volver a montar la placa de proteccioÂn despueÂs de
ESP marcha dispuestos en su orden. ESP engrasarla con LOCTITE 510.
Remonter toutes les pieÁces du cylindre de commande Remonter la toÃle de protection apreÁs l'avoir enduite de
F de vitesses placeÂ dans l'ordre. F LOCTITE 510.
Rimontare il cilindro comando marcia completo di Reinserire le viti ed avvitarle.

ITA anello OR. ITA
Zylinder des Gangschalters mit O-Ring montieren. Schrauben einsetzen und festschrauben.
D D
c d
Volver a montar el cilindro mando marcha completo de Volver a introducir los tornillos y atornillarlos.
ESP anillo OR. ESP
Remonter le cylindre de commande de vitesses Introduire les vis et visser.

F complet de bague OR. F
Reinserire asta di comando marcia dopo averla

ITA spalmata con LOCTITE 242. ITA
Gangschalterhebel mit LOCTITE 242 schmieren und

D montieren. D
e f
Volver a insertar la varilla de mando de la marcha
ESP despueÂs de engrasarla con LOCTITE 242. ESP
Introduire la tringle de commande de vitesses apreÁs

F l'avoir enduite de LOCTITE 242. F
43
INSTALLATION OF HYDRAULIC GEAR CONTROL - INSTALLAZIONE COMANDO MARCIA IDRAULICO - HYDRAULISCHER GANGSCHALTUNG
MONTIEREN - MONTAJE MANDO MARCHA HIDRAULICO - INSTALLATION DE LA COMMANDE DE VITESSES HYDRAULIQUE
F1240149 F1240150
GB a GB b
Tighten the gear control rod using a torque wrench setting of Tighten gear control cylinder screws using a torque wrench setting
25±26 Nm. of 49±51 Nm.
GB c GB d
GB e GB f
44
Serrare asta di comando marcia con una coppia di Serrare le viti cilindro comando marcia con una coppia
ITA serraggio di 25v26 Nm. ITA di serraggio di 49v51 Nm.
Den Gangschalterhebel mit einem Anziehdrehmoment Die Zylinderschrauben des Gangschalters mit einem
D zu 25v26 Nm anziehen. D Anziehdrehmoment zu 49v51 Nm anziehen.
a b
Apretar la varilla de mando a un par de torsioÂn de Apretar los tornillos de mando de la marcha a un par
ESP 25v26 Nm. ESP de torsioÂn de 49v51 Nm.
Serrer la tringle de commande de vitesses aÁ un couple Serrer les vis du cylindre de commande de vitesses aÁ
F de serrage de 25v26 Nm. F un couple de serrage de 49v51 Nm.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
45
GROUP 70
HYDRAULIC
DISMANTLING THE MAIN HYDRAULIC PUMP
70-3-40 EN
06 / 09 / 2002
KP 02 MNT
INSTRUCTIONS FOR REPLACING THE SEALS
PUMPS SERIES KAPPA 30/30 "LOAD SENSING"

General Recommendations
Make sure the components have not been damaged in transport. Always work in a clean
environment. Clean all parts (except seals) with a solvent and blow clean, dry air through them
before reassembly. Be careful not to damage the seals. Avoid negligence or any other
deterioration of machined surfaces. The parts must be assembled without resistance which
would indicate incorrect assembly or the parts assembled are not exactly correctly positioned
with respect to each other. If hand pressure is inadequate to place a part fully in position, use a
rubber mallet. Never use a metal head!! Make sure that the torque settings used for the screws
match the values given in the appropriate tables.
List of tools:
Vice
Special tool for installing the shaft seal
Vertical press
Tool for protecting the shaft seal on assembly of the front flange
Special tool for the rotation test on the pump after assembly
Torque wrench
Oil and grease
Emery cloth
ANSI B92.1 classe 1

13 Dents - 16/32 D.P.
Fond plat - Centrage sur flancs
R 2.50 Angle de pression 30° 2.00
AMNB004 0/0499
12.50
7
M8
29.00
40.00
27.50
25.00
AMNMO400/0499
5.50
5.00
18.5
1.6
0
26.00 -0.10
Arrête vive
+0.10
4
0
ø3
15.00
+0.07
=
28.00
21.80 +0.02
19.15
+0.20
24.00 +0.10
3.2 1.6
=
+0.20 1.6
25.00 +0.10
Special tool for installing the shaft seal 14.00 15.00 3.2 1.6
Special tool for the rotation test on the

pump after assembly
THIS CATALOGUE REPLACES UPDATES

Code Edition Code Edition New Changes
KP 04 MNT 05/1999
OPERATIONS TO PERFORM TO REPLACE THE SEALS ON KP 30 PUMPS -
LOAD SENSING VERSION A
Fit the jaws of the vice with clamps made of
aluminium or soft material to avoid damaging the
machined surfaces of the pump.
Position the pump vertically with the driveshaft

pointing downwards, then tighten the vice. Be careful
A1 not to damage the machined parts while tightening.
Draw a mark with a felt tip on the pump to ensure

correct part reassembly.
Loosen the mounting screws with a wrench.
A2
Remove the rear cover and screws.
A3
Remove the ring seal
A4
1
A
Loosen the mounting screws using a wrench.
A5
Remove the screws.
A6

pointing upwards.
Remove the front cover with a rubber mallet.
A7
Draw a mark with a felt tip on the bearing and the

body to ensure correct part reassembly.
A8
2
A
Release the bearing.
A9
Remove the input and output shafts.
A10
Release the lower bearing and draw a mark on the

bearing and the body to ensure correct reassembly.
A11
Remove the ring seal
A12
3
A
Remove the compensation ring and reinforcement on
the four bearings and replace with grease.
A13
Place the lower bearing carefully into the body until it

comes into contact with the body; the seal must be
pointing downwards.
For orientation, the previously drawn mark (on the

pump body and the bearing) will prevent any error on
A14 reassembly.
Insert the input and output shafts into the body of the
pump until they are in contact with the lower bearing.
Be careful not to reverse the positions of the shafts;

respect the original position.
A15
Place the upper bearing carefully into the body until it

comes into contact with the gears; the seal must be
pointing upwards.
For orientation, the previously drawn mark (on the

pump body and the bearing) will prevent any error on
A16 reassembly.
4
A
Place the cover on the workbench and remove the
ring using pliers.
A17
Set the front cover turned downwards. Release the

shaft seal using a tool. Be careful not to damage the
machined parts.
A18
Smear a thin layer of grease around the shaft seal to

facilitate assembly. Now use the special tool to install
the shaft seal and push it into place in its housing until
the seating of the ring becomes visible.
A19
Insert the ring using pliers.
A20
5
A
Coast the tool used to protect the shaft seal when
mounting the front cover, with uncontaminated grease
or oil and insert it onto the input shaft.
Fit the front cover without damaging the lip of the seal,
making sure that the guides are slotted into their
A21 housings.

not the damage the machined parts while tightening.
A22 Tighten the screw using a torque wrench set to torque

14 (daNm), using diagonally opposed movements.
Insert the ring seal with grease.
A23
Place the rear cover on the vice.
Loosen the stopper using a wrench.
A24
6
A
Remove the ring seal from the stopper and replace it
with a new one.
A25
Tighten the spring-loaded stopper using a torque

wrench set to torque 5 (daNm).
A26
Loosen the stopper using a wrench.
A27
Remove the ring seal from the stopper and replace it

with a new one.
A28
7
A
Tighten the stopper using a torque wrench set to
torque 5 (daNm)
A29

not to damage the machined parts while tightening.
Assemble the valve, screwing the assembly by hand.
A30 The previously drawn marks (on the pump body and
the cover) prevent any possibility of making mistakes
on reassembly.
Tighten the screw using a torque wrench set to torque

7 (daNm), using diagonally opposed movements.
A31
To check the torque in operation, turn the input shaft

to make sure that it turns freely and that no mistakes
have been made during assembly.
A32
8
Our policy is to work towards constant product improvement; for this reason product characteristics are subject to
change without prior notification.
9
PUMP (details)
10
PUMP (details)
1 – SPRING PLUG FOR LS VALVE

2 – PUSHING SPRING FOR LS VALVE
3 – THROTTLING GRUB SCREW (RED)
4 – SPRING FOR LS VALVE
5 – DRIVE GEAR
6 – COVER
7 – CIRCLIP
8 – SHAFT SEAL BAUD
9 – SLEEVE BEARING
10 – O-RING SEAL
11 – THRUST PLATE
12 – DRIVEN GEAR
13 – O-RING SEAL
14 – BACK-UP RING
15 – BODY
16 – REAR COVER
17 – SCREW
18 – WASHER
19 – SCREW
20 – WASHER
21 – STEEL BUSHES
23 – PLUG
24 – SCREW
25 – O-RING SEAL
26 – FILTER
27 – PLUG
28 – THROTTLING GRUB SCREW
29 – SPOOL
30 – O-RING SEAL OR
11
12
DISMANTLING THE MAIN HYDRAULIC PUMP
70-3-47 EN
20 / 12 / 2007
INDEX
1 - DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 - REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
VIEW OF PUMP AA10VO ASSEMBLED
3
1 - DISMANTLING
- Remove the governing unit
On refitting, make sure the pivoting choke

in the governing unit is properly positioned
(Slot in line with the oil circulation holes).
- Position the pump vertically.

- Note the position and remove the cylinder head.
- Remove the cylinder head, holding the slide-face in

position.
4
- Remove the seals.
- Remove the conical bearing at the end of the shaft.
- Remove the spacer shim.
- Position the pump horizontally.

- Remove the axial piston, holding the pistons and
contact plate in position.
5
- Remove the control cylinder stop.
- Extract the piston from the control cylinder.

- Swivel the pump plate to release the piston more
easily.
- Remove the control cylinder rod.
NOTE : The head of the rod has a particular shape, so

you might need to move the plate in order
to remove it.
- Remove the tilting plate.
6
- Remove the spring from the plate recall.
- Remove the drive shaft and lower bearing assembly.
- Remove the contact cups from the tilting plate.

Locking screw
- Remove the retaining rings.
7
- Tighten the metal screws in the dishes on the shaft
seal.
- Remove the shaft seal by pulling on the screws with
pliers.
2 - REMOUNTING
- Repeat the operations in reverse order, taking the fol-

lowing information into account:
- Put a new shaft seal in position using a spacer.

- Refit the retaining rings.
- Make sure the slide-face is correctly positioned

(notch) with respect to the cylinder head (lug).
Slot
Stop
- Position the cylinder head seal carefully.
8
- If the position of the cylinder head was not noted on
dismantling, use the oil circulation holes to remount
the cylinder head on the pump body.
- Make sure the control cylinder rod is properly inser-

ted in the housing provided on the plate. Swivel the
plate to help fit the rod in place.
- Pre-tension on the bearings : Pre-tension must be set

to 0 to 0.05 mm.
- Adjust spacer 1 to change the setting.
Fill the pump casing with hydraulic oil

after each operation.
9
STANDARD TIGHTENING TORQUE TO USE WHEN IT IS NOT GIVEN IN THE DISMANTLING AND REMOUNTING INS-
TRUCTION
TIGHTENING TORQUE IN N.m (*) (*) - Tightening torques are given for
Thread Ø Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9 black or galvanized fittings with light
M3 0,54 0,76 1,16 1,7 2 lubrication.
M4 1,24 1,74 2,66 3,91 4,57 - Tightening torques are given for
M5 2,47 3,46 5,2 7,7 9 automatically triggered and reset
M6 4,29 6 9,1 13,4 15,7 torque wrenches and direct display
M8 10,4 14,6 22 32 38 torque wrenches.
M10 20 28 44 64 75 - For further information, see standard
M12 35 49 76 111 130 NF E25-030.
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200
Valve DSR
10
DISTRIBUTOR DISASSEMBLY
70-3-54 EN
30 / 09 / 2003
INDEX
DISTRIBUTOR SX 14 : GENERALITY
1 - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 - TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 - BASIC RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1 General rules regarding connecting the distribution block . . . . . . . . . . . . . . . .7
4 - REMOVING / REMOUNTING THE SX 14 BLOC . . . . . . . . . . . . . . . . . . . . . . .7

4.1 General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.2 Removing the SX 14 block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.3 Remounting the SX 14 block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 - SX BLOCK REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5.1 Changing the LS limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.2 Changing the flow rate governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.3 Disassembling the flow divider governing subassembly . . . . . . . . . . . . . . . . . .8
5.4 Disassembling the sweepingvalve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.5 Changing the secondary pressure relief valve . . . . . . . . . . . . . . . . . . . . . . .10
5.6 Disassembling a slide valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.7 Disassembling / assembly of the distribution block . . . . . . . . . . . . . . . . . . . .12
6 - SPECIFIC TIGHTENING TORQUE
6.1 MLT 845 -120 LSU / MLT 940 L -120 LSU . . . . . . . . . . . . . . . . . . . . . . . . . .14
3
1 - INTRODUCTION
1.1 PREFACE
This manual deals with instructions relating to servi-
cing and maintenance of the SX 14 distribution block,
for checks and servicing with regard to the machine's
hydraulic circuit to which it is connected, it is very
important to consult the relevant chapter of this
manual.
Installation, connection and maintenance of this

appliance must be carried out by a qualified technician
in compliance with current technical standards and
rules of cleanliness specific to this type of installation.
All information, illustrations, guidelines and characte-

ristics contained in this publication are based on the
latest information on the product available at the time
of going to press. In its effort to enhance quality,
Manitou reserves the right at any time to make modifications without further notice and shall not be held liable the-
refor.
1.2 SAFETY INSTRUCTIONS

Safety rules and other important comments requiring your greatest attention are presented in the following way in
this manual :
Instructions to be followed imperatively so as to ensure your personal safety

and avoid the risk of damage to the equipment during operation.
4
2 - TROUBLE-SHOOTING
Before applying one of the malfunction analysis procedures to detect the fault and before disassembling the distri-
bution block, it is imperative to carry out a preliminary search on the machine's hydraulic circuit, in order to rule out
any possible failures resulting from causes external to the sx 14 distribution block.
Faults observed through abnormal operation of the receivers connected to the distribution block.
Observed results Likely causes Further checks Remedies
Lack of power at all recei- 1- Faulty LS limiter Measure the pressure Change the LS limiter
vers (see chapter : 70 - 6 - _ _) (cf. § 5.1)
2 - LS limiter out of adjustment Adjust the setting
Lack of power at a single 1 - Secondary pressure relief Recalibrate to the original

receiver valve or shock protection pressure
valve out of adjustment (see chapter : 70 - 6 - _ _)
2 - Secondary pressure regu- Change the secondary

lating valve stuck on pressure relief valve (cf. §
"open" (return to tank) * 5.5)
Check the assist pressure
Lack of speed in execution Lack of slide valve control Control procedure

of one or all movements (see chapter : 70 - 6 - _ _)
1 - Check the slide valves'

clearance
Lack of speed in execution 1 - Incorrect slide valve If travel incorrect : change
of a single movement travel or lack of slide the body + slide valve unit
valve freedom (cf. § 5.7 and 5.6)
Change the body + pres-
2 - Individual pressure sure balance unit (cf. §
balance blocked 5.7)
1 - Control piston sliding
freely
Turning abnormally stiff 1 - Wrong flow divider set- Change the control sub-
ting assembly (cf. § 5.3)
2 - Control piston blocked
Change the body + control
device unit
(cf. § 5.7 and 5.3)
No simultaneity of move- 1 - Individual balance jet Remove and clean the indivi-
ments blocked dual balance jet (cf. § 5.7)
Change the body + control

2 - Individual balance bloc- device unit
ked
Change the LS flow governor
3 - Leakage in the LS line (cf. § 5.2)
5
Faults observed through abnormal operation of the machine
The I.C. engine remains Flow governor blocked Check ∆P in neutral Change the flow governor
charged after the slide (cf. § 5.2)
(see chapter 70 - 6 - _ _)
valves return to neutral
Faults observed through abnormal operation of the distribution block controls.
Increased effort on Distribution block assem- Check the tightening torque Loosen and set the torque
controls or faulty return bly tie-bars too tight to :
(cf. § 6)
FIRST RELEASE THE

DISTRIBUTION BLOCK
FROM ITS MOUNTING
POINTS
Slide valve seals worn out Change the slide valve

seals (cf. § 5.6)
Faults observed through visual control
Oil leaks at the slide valve Faulty slide valve seals Change the slide valve
seals (cf. § 5.6)
Change the slide valve Faulty seals Remove the limiter or the
seals (cf. § 5.6) cap and change the joints
Oil leaks between mem- Faulty seals between Remove the distribution
bers members members and change the
seals (cf. § 5.7)
6
3 - BASIC RULES
3.1 GENERAL RULES REGARDING CONNECTING THE DISTRIBUTION BLOCK
- When removing the block, immediately seal the inlet openings so as to prevent contamination of the hydraulic circuit.
- When remounting the block, remove the plastic caps from the inlet openings and pipes just before making the
connections.
- Do not tighten the connectors beyond the tightening torque recommended in the assembly instructions.
- At each servicing, check the quality of the oil and the level of filtering of the hydraulic system.
- Teflon, hemp and gasket seal paste are strictly not to be used.
- The pipework and connectors are not to be subjected to any stress.
4 - REMOVING / REMOUNTING THE SX 14 BLOC

4.1 GENERAL RECOMMENDATIONS
Before removing the sx 14 distribution block from the machine it is vital that the block and its surroundings
should be properly cleaned with a high pressure cleaner.
As no impurity from the surrounding area must get into the hydraulic circuit, place plastic seals on the pipes and
inlet openings immediately upon removal.
Wear protective clothing and used the appropriate equipment so as to avoid any accidents,
notably with the fluid.
Use the appropriate hoisting rings and other handling arrangements.
Place all machine receivers connected to the distribution block in the idle position (resting on the ground,
with droop stop etc.) so as to avoid accidents caused by uncontrolled movements when disconnecting
the hydraulic circuit.
With the machine switched off, work the distribution slide valves to release the pressure build-up.
4.2 REMOVING THE SX 14 BLOCK

- Place a vacuum pump on the tank so as to reduce oil leakage when disconnecting the connectors.
- Place sealing caps on the pipework immediately upon disconnecting.
- Take care to collect any leaking oil in an appropriate receptacle.
- Loosen the mounting screws and remove the distribution block.
4.3 REMOUNTING THE SX 14 BLOCK

- Ensure that the contact faces are perfectly clean.
- Check that the bearing surface on the machine is perfectly flat (tolerance 0.5 mm).
- Check the states of the pipework connector seals.
- In the event of extended storage, clean the block.
- Present the distribution block correctly onto the machine and screw it on.
- Connect the pipework to the block, following the connection diagram and the recommended tightening torques.
- Check the hoses for clearance to avoid twisting and rubbing.
- Once correctly mounted, proceed with commissioning :
- Cancel the setting on the LS limiter before commissioning the machine,
- Work the distribution slide valves,
- Set the max. pressure value with the LS limiter whilst keeping a stop function.
7
5 - SX 14 BLOCK REPAIR PROCEDURES
5.1 CHANGING THE LS LIMITER
NB : This operation does not require removal of the

distribution block from the machine.
Machine switched off :

- Place all machine receivers connected to the distri-
bution block in the idle position.
- Work the distribution slide valves to release the
pressure build-up.
NB : Collect any leaking oil in an appropriate recep-

tacle.
- On the inlet member, unscrew the LS limiter (17 mm wrench).
Remounting : tightening torque (cf. § 6)
5.2 CHANGING THE FLOW RATE GOVERNOR


pressure build-up.
NB : Collect any leaking oil in an appropriate receptacle.
- On the inlet member, unscrew the flow rate governor

(22 mm wrench)
Remounting : tightening torque (cf. § 6)
REMOVING AND REPLACING THE STRAINER
- Using flat nose pliers, extract the strainer from the

governor.
strainer
Warning: do not damage the O-ring on the end of the
governor.
8
5.3 DISASSEMBLING THE FLOW DIVIDER GOVERNING SUBASSEMBLY
NB This operation does not require removal of the distribution block from the machine.

- Place all machine receivers connected to the distribution block in the idle position.
- Work the distribution slide valves to release the pressure build-up.
NB : Place a vacuum pump on the tank so as to reduce oil leakage during this operation.
Collect any leaking oil in an appropriate receptacle.
- Unscrew the cap with a 12 mm hexagon socket screws key.

- Remove the stop and spring.
Remounting : tightening torque : (cf. § 6)
- Change the faulty parts.

- Change the O ring joints on the caps.
- Re-assemble in reverse order of disassembly.
Cap
Stop
Spring
Assembled piston
9
5.4 DISASSEMBLING THE SWEEPINGVALVE
NB This operation does not require removal of the dis-

tribution block from the machine.

pressure build-up.
- On the outlet member, unscrew the sweeping valve

cap with a 12 mm hexagon socket screws key). Cap
Remounting : Block
- Change the cap O ring joint on the cap
- tightening torque : (cf. § 6)
Spring
- Remove : - the block, Ring

- the spring,
- the ring, Piston
- the piston.
- Re-assemble in reverse order of disassembly.
5.5 CHANGING THE SECONDARY PRESSURE

RELIEF VALVE


pressure build-up.
NB : Collect any leaking oil in an appropriate receptacle.
On the relevant distribution member, unscrew the secondary pressure relief valve with a flat 24 mm wrench.
Remounting :
- Set the pressure relief valve to the specified value,
- Mount the secondary pressure relief valve onto the distribution member, tightening torque : (cf. § 6)
- Fit a new adequate locking cover.
10
5.6 DISASSEMBLING A SLIDE VALVE


pressure build-up.
NB : Place a vacuum pump on the tank so as to

reduce oil leakage during this operation.
Collect any leaking oil in an appropriate receptacle.
- Remove the mounting screws and cover (5 mm

hexagon socket screws key).
- Remove the cup and spring.

- Remove the O ring joint from the cover.
- Pull out the slide valve from the distribution member.
Remounting
- Fit new seals with grease.
Direction of slide valve assembly.
11
5.7 DISASSEMBLY / ASSEMBLY OF THE DISTRI-
BUTION BLOCK
PRELIMINARY OPERATIONS :
- Remove the distribution block from the machine (cf. § 4).
- Remove the 3 assembling nuts (13 mm socket wrench).
- Remove the outlet member.

- Separate the distribution members from the inlet
member.
- Change the O ring joints placed between the distri-
bution members, the inlet member and the outlet
member.
- When changing the inlet member, remove the tie-
bars.
- Re-assemble in reverse order of disassembly, taking
care to tighten the tie rods to the recommended tigh-
tening torque.
- Ensure component surfaces are clean beforehand.
Disassembling the individual pressure balance
- Unscrew the cap with a 7 mm hexagon socket screws key.
- Remove the piston from the balance.

- Clean the piston jet with compressed air.
- Check the state of the bore on the body.
Re-assembly : change the cap backing ring and O ring.
12
Disassembling a charge holding valve
Unscrew the cap with a 5 mm hexagon socket screws

key.
- Remove the valve and the spring.

- Visually check the state of the parts.
- If necessary, change the faulty parts.
Re-assembly :
- Change the O ring on the cap
- Tightening torque : (cf. § 6)
13
6 - SPECIFIC TIGHTENING TORQUE
tightening torques specified in Nm to ± 10%. .
6.1 MLT 845 -120 LSU / MLT 940 L -120 LSU
item. torque, Nm
Input member :
1 LS pressure limiter : 45
2 LS flow regulator : 20
3 DLS / LS selector : 20
4 Priority valve seat : 10
5 Priority valve plug : 100
6 Tie rods : 30
Disstribution member :
7 Non return valve : 30
8 Balance cap : 60
9 Secondary pressure limiter : 70
10 Hydraulic control unit : 10
11 Return unit : 10
12 EMS module control piston : 10
13 EMS module : 15
Outlet member :
14 Deflection valve cap : 100
15 Tie rod nuts : 42
14
Deflection valve
cap
6 15 14
Secondary pressure
limiter
Return unit
11
15
8
10 Hydraulic control unit
Balance cap
5 EMS modue control
Priority valve
12 piston
plug
DLS / LS
selector
3
7
Non return valve
13
EMS module
1
4 Pressure
Priority valve limiter
seat
2
Flow regulator
16
HYDRAULIC DIAGRAM
70-6-233400 EN

15 / 11 / 2007
70-6-233400EN 2 15/11/2007
CONTENTS
-HYDRAULIC DIAGRAM
LEGEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MT 1033 H L Turbo Série 2-E2 N° : 230682 .......................... 5
MT 1033 H L Turbo Série 2-E2 N° : 230683 . . . . . . . . . . . . . . . . . . . . . . . . . . 6

MT 1033 H L Turbo Série 3-E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
15/11/2007 3 70-6-233400EN
HYDRAULIC DIAGRAM MT 1033 H L TURBO SÉRIE 2-E2
MT 1033 H L TURBO SÉRIE 3-E2
BT Transfer box
VACM(O) Movements cut-off valve (Option)
VAFR(O) Trailer braking valve (Option)
CA Suction strainer VAI Insulation valve
CAR Back pressure valve VAP Control valve
CPD Double piloted valve VC Compensation cylinder DE
CSD Double safety valve VCD Levelling cylinder DE
CSP Piloted safety valve VDAR Rear steering cylinder DE
VDAV Front steering cylinder DE
VI Tilting cylinder DE
D Valve bank (4 or 5) sections VL Lifting cylinder DE
EA Attachment section VPV Gear change cylinder
ECD Levelling section VT1 Telescoping cylinder 1 DE
EE Inlet section VT2 Telescoping cylinder 2 DE
EF Closing section VVT(O) Locking carriage cylinder (option) DE
EI Tilting section
EL Lifting section
ET Telescope section
NOTE : 1 - The main relief valve’s pressure, on inlet
D3 Driving valve bank 3 positions sections are given at engine’s maximum
Position 1 : Steering short rating.
Position 2 : Steering front wheel 2 - The secundary valve’s pressure, are
Position 3 : Crab position given at 1000 rpm of the engine.
3 - Pressure relief valve’s control must be
EVPV Gear change electrovalve done at an oil temperature from 50°C to
EVTF(O) Jib head electrovalve (option) 60°C.
FDAV Front disk brake

FR Return filter
FT Transmission fllter
M I.C. Engine
Rating slow unladen
Nominal rating load
Max. Rating unladen
MC Master cylinder
MH Hydrostatic motor
N Level
P Hydraulic pump
PAAV Front attachment fitting
PAAV(O) Front attachment fitting (option)
PD Steering pump
PFR(O) Trailer braking fitting (Option)
PH Hydrostatic pump
PP Pressure point
PRF(O) Drain-back fitting (Option)
R Hydraulic tank
RH Hydraulic cooler
RLF Braking oil tank
RPI Inching pressure reducer (TH7)
SCFR(O) Trailer braking circuit selector (Option)
70-6-233400EN 4 15/11/2007
HYDRAULIC DIAGRAM MT 1033 H L TURBO SÉRIE 2-E2 N° : 230682
3
2
1 VVT(O)
VAI
AV AR
3 2 1
A B T
Gicleur VCD PAAV
Ø1.2
3 2 1
C2
D3 C4
PAAV(O) C3
P C1
Gicleur
Ø1.2
R L
PD 200b 200b C2 C1
CPD 325b 325b
EVTF(O)
P1 P2
200 cm3/tr
V2 V1
PRF(O)
LS 140b
SCFR(O) VT2
V1 V2 PFR(O)
T P
Gicleur
Ø1 S Gicleur VL VI
Ø1 C1 C2
+15
CSP 315b 0
P T C1 C2
+15
CSP 315b 0
110b
OPTION FREINAGE REMORQUE
V1 V2
Y
VAFR(O) C1 C2 110b
N B CSP 315b +15 V1 V2 VT1
RLF 0
110b
VC
B2 B1 V1 V2 C1 C2
300b 300b
Gicleur
Ø1
CSD
MC T P V1 V2
TH7
A
A1
P X1 B A2 B2 A3 B3 A4 B4 A5 B5 T
280b 280b 190b 190b
FT
15 microns VACM
absolu
Y
a b PP P
BT MB Fe Fa1 Fa PS T1
LS CF EF B
M1 T B U
MH 270b
a EE ECD EL EI EA ET ES
P M
43,77 cm3/tr Y1
D
PH 2 1
MACD
b
A
T P
MA S MH G X2 X1 T2 2
Fs
T G X1 X3 A
EVACD
3 1
CAR
ES. AV.
2b
ES. AR.
FDAV VDAV VDAR

VP
A B
EV
P T
FR
6b
5b
10 microns absolu (1ère monte)

RF 15 microns absolu (pièce rechange)
N CA
Niveau moyen: 104L 125 microns
absolu
R 128 litres Réserve direction
15/11/2007 5 70-6-233400EN
HYDRAULIC DIAGRAM MT 1033 H L TURBO SÉRIE 2-E2 N° : 230683
MT 1033 H L TURBO SÉRIE 3-E2
2
3 1
VVT(O)
VAI
AV AR
3 2 1
VI
A B T
PAAV C1 C2
3 2 1
CSP 315b
+15
D3 C2
0
P C4
PAAV(O) C3
C1 110b
R L
V1 V2
PD 200b 200b
VCD VC
200 cm3/tr EVTF(O)
P1 P2
LS
140b
SCFR(O) C1 C2
V1 V2 CPD 325b 325b
T P
Gicleur
Ø1 S Gicleur VT2
Ø1 V1 V2
VL
Ø1
VAFR(O) P T B
C1 C2
VAP
OPTION FREINAGE REMORQUE CSP 315b
+15
0
Y A
RLF N B 110b
PRF(O) V1 V2
C1 C2 VT1
B2 B1 335b
Gicleur
PFR(O)
Ø1
C1 C2
MC T P 30b CSP
300b 300b
V1 V2
CSD
RPI V1 V2
A
PP
P A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 T
280b 280b 190b 190b D
FT
15 μ
absolu Y
a b
BT MB Fe Fa1 Fa PS T1
LS CF EF B
M1 T B U VACM(O)
MH 250b
a P
EE EA ECD EL EI ET EF
43,77cm3/tr M
PH
b
A
MA S MH G X2 X1 T2
Fs
T G X1 X3 A
CAR
ES.AV.
2b
ES.AR.
FDAV VDAV VDAR

VPV
A B
EVPV
P T
FR
6b 5b
10 μ absolu (1ère monte)

RH 15 μ absolu (pièce rechange)
N CA
Niveau moyen:
125 μ
104L
absolu
Capacité 128 litres
R Réserve direction
70-6-233400EN 6 15/11/2007
HYDRAULIC DIAGRAM
70-6-245421 EN
23 / 01 / 2007
CONTENTS
– HYDRAULIC DIAGRAM
MLT 742 H Turbo LSU Série 2-E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3
HYDRAULIC DIAGRAM MLT 742 H TURBO LSU SÉRIE 2-E2
A Accumulator
P Hydraulic pump
PAAR(O) Rear attachment socket (option)
BT Transfer box PAAV Front attachment socket
PAAV(O) Front attachment socket (option)
PCR Cooler circuit pump
CA Suction strainer PD Steering pump
CAR Back pressure valve PFR(O) Trailer braking fitting (option)
CR(O) Towing hook (Option) PH Hydrostatic pump
CSP Piloted safety valve PP Pressure point
PRF(O) Drain-back fitting (option)
D Valve bank (4) sections

EA Attachment section R Hydraulic tank
EA(O) Attachment section (option) RAD Radiator
EE Inlet section RF Cooler
EI Tilting section RLF Brake fluid tank
EL Lifting section
ES Outlet section SCFR(O) Trailer braking circuit selector (option)
ET Telescope section
D3 Steering valve bank 3 positions TH7 Joystick TH7
Position 1 : Steering short
Position 2 : Steering front wheels
Position 3 : Crab position VAFR(O) Trailer braking valve (option)
VAI Insulation valve
VACM(O) Movements cut-off valve (option)
ESAR Rear axle VC Compensation cylinder DE
ESAV Front axle VDAR Rear steering cylinder DE
EVAA(O) Rear attachment electrovalve (option) VDAV Front steering cylinder DE
EVPV Gear change electrovalve VI Tilting cylinder DE
EVTF(O) Jib head electrovalve (option) VL Lifting cylinder DE
EV5E(O) Section 5 electrovalve (option) VPV Gear change cylinder
VT Telescope cylinder DE
VVT(O) Locking carriage cylinder DE (option)
FDAR Rear disk brake
FEMS EMS head filter
FR Return filter NOTA : 1 - The main relief valve’s pressure, on inlet
FT Transmission filter sections are given at engine’s maximum
rating.
2 - The secundary valve’s pressure, are given
M I.C. engine at 1000 rpm of the engine.
Slow rating unladen 3 - Pressure relief valve’s control must be
Nominal rating load done at an oil temperature of 50°C.
Max rating unladen
MA Joystick
M1 Attachment
M2 Telescope extended
M3 Attachment
M4 Telescope retracted
1 Lifting
2 Lowering
3 Tilting
4 Levelling
MC Master cylinder
MH Hydrostatic engine
N Level
4
HYDRAULIC DIAGRAM MLT 742 H TURBO LSU SERIE 2-E2
x
VVT(O) 1
VAI PAAR(O)
2 (1 ou 2 PRISES)
3
VL PAAR(O)
4 (2 PRISES)
PAAV
VT CR(O)
VI
C2
C4
PAAV(O) C3
C1 C1 C2
C1 C2 C1 C2
x
315b
+15 C3
335b 300b 0
2 A B T PRF(O) C2
3 1
x
CSP 110b CSP
3 2 1
30b CSP EVAA(O)
V1 V2 V1 V2 V1 V2 C4 C1
AV AR D3 EVTF(O) P1 P2
3 2 1 P VC
R L
M1 B T U BT PD 200b 200b
x
x
MH C1 C2 M P2 P1
CSP
x
a
200 cm3/tr
200b
x
OPTION FREINAGE REMORQUE V1 V2
SCFR(O) LS 140b
b
V1 V2 PP
x
ES. AV.
T P M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
S
DLS
x
ES. AR.
T G X1 X3 A
P T P
Y
FDAV VDAV VDAR FD 22,5 bar
VAFR(O)
N LS
PFR B 270 bar
T
VP RLF T T T T T
B B A B
B2 L N
D EE EA 200 bar ET 190 b 280 b EI 280 bar EL EA(O) ES
A
x
VACM(O) Y pst a a a
0,7 L. A B
13 b Gicleur Ø1
T P 2 4
EVP MC
FT P T P
B A
TH7 FEMS EV5E(O)
A 10 microns
15 microns 3 1
absolu
MA P T
X Y
1 3 2 4
a b
MB Fe Fa Fa1 PS T1
x
x
B
B
MA
S M5
M1 M3
P 63 cm3/tr M M6
M2 M4
PH
L L1 L2 S
M8 M7
A
x
x
MA Fs S MH G X2 X1 T2
CAR CAR FR
RH 0.5 b 2b 6b
5b
10 microns absolu (1ère monte)
15 microns absolu (pièce rechange)
RF
PCR 14 cm3/tr
N CA
Niveau moyen : 125 microns
104 litres absolu
5
HYDRAULIC DIAGRAM
70-6-268628 EN
15 / 11 / 2007
70-6-268628EN 2 15/11/2007
CONTENTS
-HYDRAULIC DIAGRAM
MLT 742 H Turbo LSU Série 3-E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15/11/2007 3 70-6-268628EN
A Accumulator R Hydraulic tank

RAD Radiator
BT Transfer box RF Cooler
RLF Braking oil tank
RPI Inching pressure reducer (TH7)
CA Suction strainer
CAR Back pressure valve
CR(O) Towing hook (Option) SCFR(O) Trailer braking circuit selector (Option)
CSP Piloted safety valve
VACM(O) Movements cut-off valve (Option)

D Valve bank VAFR(O) Trailer braking valve (Option)
EA Attachment section VAI Insulation valve
EA Attachment section (Option) VC Compensation cylinder DE
EE Inlet section VDAR Rear steering cylinder DE
EF Closing section VDAV Front steering cylinder DE
EI Tilting section VI Tilting cylinder DE
EL Lifting section VL Lifting cylinder DE
ET Telescope section VPV Gear change cylinder
VT Telescoping cylinder DE
D3 Driving valve bank 3 positions VVT(O) Locking carriage cylinder DE (Option)
Position 1 : Steering short
Position 2 : Steering front wheel
Position 3 : Crab position
NOTE : 1 - The main relief valve’s pressure, on inlet
sections are given at engine’s maximum
EVAA(O) Rear attachment electrovalve (Option) rating.
EVPV Gear change electrovalve 2 - The secundary valve’s pressure, are
EVTF(O) Jib head electrovalve (Option) given at 1000 rpm of the engine.
EV5E(O) Electrovalve - 5th sections (Option) 3 - Pressure relief valve’s control must be
done at an oil temperature from 50°C to
60°C.
FDAR Rear disk brake
FEMS EMS filters
FR Return filter
FT Transmission fllter
M I.C. Engine
Rating slow unladen
Nominal rating load
Max. Rating unladen
MA Joystick
MC Master cylinder
MH Hydrostatic motor
N Level
P Hydraulic pump
PAAV Front attachment fitting
PAAV(O) Front attachment fitting (option)
PCR Radiator circuit pump
PD Steering pump
PFR(O) Trailer braking fitting (Option)
PH Hydrostatic pump
PP Pressure point
PRF(O) Drain-back fitting (Option)
70-6-268628EN 4 15/11/2007
x
1
2 A B T VVT(O) PAAR(O)
3 1 2 (1 ou 2 PRISES)
3 2 1
VAI
AV AR D3
3 2 1 3
P VL PAAR(O)
M1 B T U BT R L 4 (2 PRISES)
PD 200b 200b
x
MH PAAV
CR(O)
a VT
200 cm3/tr VI
C2
C4
OPTION PAAV(O)
FREINAGE REMORQUE 140b C1 C3
LS C1 C2 C1 C2 C1 C2
SCFR(O) CSP CSP CSP
x
b 335b 300b 315b
+15
0
V1 V2
P
PRF(O)
T C3
ES.AR.
ES.AV.
S EVTF(O) 30b C2
V1 V2 110b
x
P1 P2 V1 V2 V1 V2
EVAA(O)
x
x
T G X1 X3 A VC C4 C1
P T
FDAV Y
VDAV VDAR FDAR VAFR(O)
N LS
P2 P1
PFR B
VPV
RLF M
C1 C2
A CSP
x
B2 L N
Gicleur Ø1
x
0,7 L. A B 200b
13 B.
x
V1 V2
EVPV T P
MC
FT P T P
B A
RPI PP
x
A
15 μ M LS D B1 A1 B2 A2 b B3 A3 b B4 A4 b B5 A5
absolu DLS
P
X Y
22,5 b.
a b
MB Fe Fa Fa1 PS T1
B
x
T 270 bar
B
T T T T T
B B A B
D EE EA 200 bar ET EI 280 bar EL EA(O) EF
Y pst a 190 b. 280 b. a a
VACM(O)
P 63 cm3/tr M
2 4
PH
L L1 L2 S
A FEMS EV5E(O)
10μ 3 1
x
x
x
FR
RAD CAR CAR 6b MA P T
0.5 b 2b 5b
RF 10 μ absolu (1ère monte)

15 μ absolu (pièce rechange)
1 3 2 4
PCR
14 cm3/tr
MA
N CA
125 μ
Niveau moyen: absolu
104L
R Capacité 128 litres Réserve direction
15/11/2007 5 70-6-268628EN
70-6-268628EN 6 15/11/2007
GROUP 75
HYDROSTATIC
PUMP DISASSEMBLY
A4 VG 71-180 (Série 3.2)
75-3-16 EN
10 / 01 / 2001
REPAIR
PUMP A 4 VG 71 - 180
Série 3.2
3
REPAIR INSTRUCTIONS
CONTENTS
- General repair instructions .................................................................................................................................. 5
- Seal kits and sub assembly groups ..................................................................................................................... 6
- Sub assemblies groups ......................................................................................................................................... 7à8
- Sealing of the drive shaft ...................................................................................................................................... 9
- Sealing of the boost pump ................................................................................................................................... 10
- Sealing of the control piston cover ..................................................................................................................... 11
- Sealing of the control piston cover .................................................................................................................... 12
- Sealing of the boost pressure valve .................................................................................................................... 13
- Sealing of the pressure relief valve HD ............................................................................................................. 14
- Sealing of the pressure cut-off valve .................................................................................................................. 15
- Sealing of the control device................................................................................................................................. 16
- Control device DA ................................................................................................................................................ 18
- Sealing of the regulator valve............................................................................................................................... 19
- Pump disassembly ................................................................................................................................................. 20 à 22
- Disassembly of the positioning piston ............................................................................................................... 23 à 24
- Dismantling of the cylinder .................................................................................................................................. 25
- Inspection notes...................................................................................................................................................... 26 à 27
- Positioning piston, rotary group assembly ........................................................................................................ 28
- Installation of rotary group .................................................................................................................................. 29 à 30
-Assembly of the pump ........................................................................................................................................... 31 à 33
4
REPAIR INSTRUCTIONS
General repair instructions
Attention !
Observe the following notices when carrying out repair
work at hydraulic aggregates !
Close all ports of the hydraulic aggregates.
Replace all seals.

Use only original MANITOU spare parts.
Check all seal and sliding surfaces for swear.

Attention : Rework of sealing area f. ex. with abrasive
paper can damage surface.
Fill up hydraulic aggregates with medium before

start-up.
5
REPAIR INSTRUCTIONS
Seal kits and sub assembly groups
Seal kit for drive shaft.
External seal kit.
Complete rotary group.
Positioning piston.
Valve plate.
6
REPAIR INSTRUCTIONS
Sub-assemblies
Control device DA
Note :
Size 71 control device as size 40 - 56 with flat seal.
Boost pump.
Control valve.
High pressure valve.
7
REPAIR INSTRUCTIONS
Sub-assemblies
Low pressure valve.
Pressure cut-off.
8
REPAIR INSTRUCTIONS
Sealing of the drive shaft
Protecting the drive shaft.

Remove retaining ring.
Screw in sheet metal screw into the holes fitted with

rubber.
Pull out shaft seal with pliers.
Press-in shaft seal with bush to stop.

Assemble retaining ring.
9
REPAIR INSTRUCTIONS
Sealing of the boost pump
Note !
* mount chamfered side facing
cover.
Mark position,
remove fixing screws.
Pry-off cover.
Check :
O-ring, groove, gliding surface, connection plate.
10
REPAIR INSTRUCTIONS
Sealing of the control piston cover
Attention !
Check correct mechanical 0-position.
Mark position.
Rotate cover and release by tapping gently with

hammer.
11
REPAIR INSTRUCTIONS
Sealing of the control piston cover
Mark cover. Must be fixed, loosen counter nut, hold

adjustment screw.
Remove cover.
Lift off by turning the setting screw.
Check !
O-ring (1), groove (2), housing (3).
12
REPAIR INSTRUCTIONS
Sealing of the boost pressure valve
Remove valve completely.

Note :
Do not change adjustment screw.
Attention !
Check valve setting after installation.
13
REPAIR INSTRUCTIONS
Sealing of the pressure relief valve HD
Remove valve completely.

Control : O-ring, housing.
Replacement of the tightening nut, record measure (*).
Attention !
After assembly check "valve setting".
14
REPAIR INSTRUCTIONS
Sealing of the pressure cut-off
Unscrew setting cartridge completely.

Control : 0-ring, housing.
Replacement of the tightening nut, record measure (*).
Attention !
After assembly check "valve setting".
15
REPAIR INSTRUCTIONS
Sealing of the control device
DA
Size
71 - 125
Size 180
Remove control device.
Note :
Size 71 : Sealing of control device as size 40 - 56 with flat seal.
Attention !
Check correct hydraulic 0-position.
16
REPAIR INSTRUCTIONS
Control front/rear electrovanne
Check :
0-rings
Outlet jet
17
REPAIR INSTRUCTIONS
Sealing of the regulator valve
Inspect orifice.
No damage.
Cover threads.
Insert O-ring.
19
INSTRUCTIONS DE REPARATION
Démontage de la pompe
Locking screw / pin
Timing adjustment screw
Remove control device.
Remove auxiliary pump.

Note :
Mark assembly position previously.
20
REPAIR INSTRUCTIONS
Pump disassembly
Mark the position of the indexing screw (1).

Record setting measure.
Set the indexing screw to disassembly position (2).
Mark position of the connection plate.

Loosen connection plate fixation.
Lift off port plate and control plate.
1. Press the cylinder to the bottom.

2. Remove fixing indexing screw.
Push off hydraulic section of rotary group.
21
REPAIR INSTRUCTIONS
Pump disassembly
Remove retaining ring and radial seal ring.
Remove drive shaft with slide hammer strokes.
Remove swash plate / bearing cups.
Remove joint pin
22
REPAIR INSTRUCTIONS
Dismantling of the control
Mark position of the cover, note measure of "zero

position".
Loosen nut.
Remove cover.
23
REPAIR INSTRUCTIONS
Dismantling of the control
Mark position of the cover.

Loosen locking screw, remove cover.
Remove positioning ring.
Fit tool device and preload spring.

Remove take-off ring.
Remove rings.
Remove safety ring.
Attention : parts are under spring load.
24
REPAIR INSTRUCTIONS
Dismantling of the cylinder
Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.
Remove safety ring.
Disc 1, 2
25
REPAIR INSTRUCTIONS
Inspection notes
Check !
Cage set (1)
Bearing cup set (2).
Check !
Bearing surfaces (1)
Check !
Sliding surface free from scoring.
Check !
Check that return device is free of scoring.
Check !
1. Splines for damage or fretting.
2. Running surfaces.
3. Groove cut by shaft seal.
26
REPAIR INSTRUCTIONS
Inspection notes
Check !
Check that there are no scratches or metal deposits on
sliding surface (1), and there is no axial play (2),
(otherwise : pistons must be replaced in sets).
Check !
Cylinder bores (1), splines (2).
Check !
Cylinder surface (1) free of scoring.
Control plate (2) without scoring.
Check !
Positioning piston -cradle linkage
Gliding stone (1), groove at the positioning piston (2),
Positioning piston.
27
REPAIR INSTRUCTIONS
Positioning piston, rotary group assembly
Assemble positioning piston.

Instruction :
Observe correct fit of the divided rings.
Insert positioning piston into the housing.

Instruction :
Remarque :
Oil positioning piston before assembly.
Insert bearing cup set.
Assemble bearing, wire, gliding stone and articulating

pin.
Assistance : Devices e.g - clamp / rubber rings / grease
28
REPAIR NSTRUCTIONS
Installation of the rotary group
Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in the
housing.
Remove auuxiliary device.
Assemble articulating pins.
Assemble device for fixation of the swivel cradle.
Assemble drive shaft with bearings and radial seal

rings.
29
REPAIR INSTRUCTIONS
Installation of the rotary group
Disc 1, 2
Assemble piston with retaining plate.

Note :
Oil piston and piston pad.
Assemble cylinder completely.
Remove assembly device.
30
REPAIR INSTRUCTIONS
Assembly of the pump
Control plate clockwise rotation - indexed in the

direction of rotation.
Note !
Noise grooves are machined - in based on direction of
rotation.
Control plate counter clockwise rotation - indexed in

the direction of rotation.
Note !
Noise grooves are machined - in based on direction of
rotation.
Basic setting - indexing screw

A4VG... 71 * = 28 +- 0,75 mm.
A4VG... 125 * = 20 +- 0,75 mm.
A4VG... 90 * = 29 +- 0,75 mm.

A4VG... 180 * = 22 +- 0,75 mm.
Insert the control plate - clockwise rotation.
Press the cylinder to the bottom (1)

Screw in the indexing screw (2).
Groove in mounting position.
31
REPAIR INSTRUCTIONS
Insert the control plate - counter - clockwise rotation.
Assemble connection plate.

Attention ! Spring preloaded !
Insert control plate into housing, guidance with two
locking screws crossing over - Finish assembly !
Locking screw - Observe adjusting measure.
1. Assemble cover.
2. Adjust zero position according to measure.
32
REPAIR INSTRUCTIONS
Attention !
Adjustments of the correct zero position to be carried
out after installation into the machine or on the bench
test.
Assemble auxiliary pump.

Note : Take care of direction of rotation.
Assemble control device.
33
REPAIR INSTRUCTIONS
34
REPAIR INSTRUCTIONS
General advice
• Make yourself familiar with the equipment of the machine.

• Only operate the machine if your are completely familiar with the operating and control elements as well as
the functioning of the machine.
• Use your safety equipment like helmet, safety shoes and hearing protection.
• Make yourself familiar with your working field.
• Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional Association and the machine manufacturer.
Before starting
• Observe the operating instructions before starting.

• Check the machine for obvious faults.
• Do not operate the machine with defective instruments, warning lights or control elements.
• All safety devices must be in a secure position.
• Do not carry with you movable objects or secure them to the machine.
• Keep oily and inflammable material away from the machine.
• Before entering the driver's cabin, check if persons or obstacles are beside or beneath the machine.
• Be careful when entering the driver's cabin, use stairs and handles.
• Adjust your seat before starting.
35
REPAIR INSTRUCTIONS
Notes
Start
• When starting all operating levers must be in "neutral position".

• Only start the machine from the driver's seat.
• Check the indicating instruments after start to assure that all functions are in order.
• Do not leave the machine unobserved when the motor is running.
• When starting with battery connection cables connect plus with plus and minus with minus.
Always connect negative (-) cable last and disconnect negative cable first.
Attention
• Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed rooms !
Hydraulic equipement
1. Hydraulic equipment is standing under high pressure.

High pressure fluids (fuel, hydraulic oil) which escape under high pressure can penetrate the skin and
cause heavy injuries.
Therefore immediately consult a doctor as otherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary devices because of the danger of accidents.
3. Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the
machine.
4. When working at the hydraulic equipment, absolutely stop motor and secure tractor against rolling away
(parking brake, shim) !
5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible
hoses.
6. In case of exchanging the ports, the functions are vice versa (f. ex. lift-up/lower) - danger of accidents !
7. Check hydraulic flexible hoses regularly and replace them in case of dammage or wear ! The new hose
pipes must comply with the technical requirements of the machine manufacturer !
Orderly disposal or recycling of oil, fuel and filters !
36
HYDROSTATIC MOTOR DISASSEMBLY
A 6 VM Serie 63
75-3-35 EN
25 / 05 / 2000
REPAIR
MOTOR A 6 VM
Serial 63
3
Recommandations Motor A 6 VM Serial 63
Repair Instructions
A Attention !
Observe the following notices when carrying out repair work
at hydraulic aggregates !
B Close all ports of the hydraulic aggregates.
C Replace all seals.

Use only original MANITOU spare parts.
D Check all seal and sliding surfaces for wear.

Attention : Rework of sealing area f. ex. with abrasive paper
can damage surface.
E Fill up hydraulic aggregates with medium before start-up.
5
Seal kits and sub assembly groups Motor A 6 VM Serial 63
Repair Instructions
1 Seal kit for drive shaft.
2 External seal kit.
3 Housing.
4 Complete rotary group.
5 Port plate with control piston.
6
Seal kits and sub assembly groups Motor A 6 VM Serial 63
Repair Instructions
9 Cover with flushing and boost pressure valve and

* Throttle pin.
* Throttle pin "as to order requirement".
7
Component groups / Control components Motor A 6 VM Serial 63
Repair Instructions
8
9
Replace seal hut Motor A 6 VM Serial 63
Repair Instructions
10 Replace seal nut.

First measure and record setting height.
11 When tightening counterhold setting screw, then check

setting height.
10
Sealing of the cover plate Motor A 6 VM Serial 63
Repair Instructions
12
13 Protecting the drive shaft.

Remove retaining ring and shim.
14 Screw in sheet metal screw into the holes fitted with rubber.
Pull out seal with pliers.
15 Press in shaft seal ring and shim with bush to stop.

- Take note of press-in depth !
- Install mark for press-in depth of safety ring.
11
Sealing of the control parts Motor A 6 VM Serial 63
Repair Instructions
Attention !
Spring load
16
17 Inspect
Drilling in housing, O-ring, groove.
18
Do not remove adjustment screw.
Inspect O-ring, O-ring groove, housing.
19 Assembly aid
Insert pin with grease.
12
13
Sealing of the control parts Motor A 6 VM Serial 63
Repair Instructions
24
25 Example : A6VM…Control - différential piston.
Disassembly position : Remove cover Pos. 2.
Attention ! Spring load.

Dimension X : Note dimension (begin of regulation).
26 1. Check of O-ring.
27 1. High pressure - small control piston side

2. Control pressure
3. High pressure - check valve
4. High pressure - check valve
14
Disassembly of the port plate Motor A 6 VM Serial 63
Repair Instructions
Différential piston :
Note dimension X.
For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder boring.
Screw Qmin Remove Qmin - screw.
Swivel rotary group to 0°.
15
16
Motor A 6 VM Serial 63
Dissassembly of the port plate Repair Instructions
28 Port plate
Mark position. Loosen screws.Removal.
29 Check O-ring.
-Stick new O-ring with some grease.

- Do not swivel rotary group.
- Piston rings to hang out from the cylinder boring.
30
- Stick control lens in sliding surface with grease.
- Assembly in reversal order.
- Mount port plate.
Rotary group vertical.
17
Remove of the positioning piston Motor A 6 VM Serial 63
Repair Instructions
Différential piston
31
32 Loosen fixing screw.
Use only socket wrench.
18
Remove of the positioning piston Motor A 6 VM Serial 63
Repair Instructions
33 Remove piston with piston ring.
34 Différential piston
Warm up fixation screw for positioning plug via boring

(screw glued - to turn out).
- Use new screw

- Note tightening torque !
19
Remove rotary group Motor A 6 VM Serial 63
Repair Instructions
36
37 Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax - stop screw.
Size 28 : M4 x 58 mm
55 : M5 x 71 mm
80 : M6 x 82 mm
107 : M6 x 92 mm
140 : M8 x 105 mm
160 : M8 x 105 mm
200 : M8 x 109 mm
38 Press out rotary group !
If the bearings are used again do not hit on the drive

shaft.
20
Remove rotary group Motor A 6 VM Serial 63
Repair Instructions
39 Or press-out with extraction device.
39
bis
21
Exchanging of the rotary group Motor A 6 VM Serial 63
Repair Instructions
Complete rotary group
Setting of hydraulic part necessary.
40
Rotary group
1. Mechanical part : Adjust drive shaft with bearing.
2. Hydraulic part : Adjustment necessary.
41
Rotary group : All parts
* Setting
Setting value, torque see service
information.
42
22
Exchanging of the rotary group Motor A 6 VM Serial 63
Repair Instructions
43 Remove fixing screw (cylinder).

Remove cylinder.
44 Disassembly retaining plate.
Screws are glued.

Use Torx-tools.
23
Inspection notes Motor A 6 VM Serial 63
Repair Instructions
45 Free of corrosion, erosion or fretting, no damage to splines

or keyways.
46 Pistons
No scoring and no pittings.
47 Center pin
No scoring and no pittings.
48 Retaining plate
No scoring and no evidence of wear.
49 1. Bores free of scoring, no evidence of wear.

2. Faces smooth and even, free of cracks and scoring.
24
Inspection notes Motor A 6 VM Serial 63
Repair Instructions
50 Control housing.
Sliding surface and side guides free of scoring and no wear.
51 Visual check :
Bearing areas free of scoring and no evidence of wear.
25
Rotary group assembly / see service information Motor A 6 VM Serial 63
Repair Instructions
Rotary group : mechanical part
Adjustment dimension * and bearing

torque see service information.
Press on bearing.
Do not exeed bearing torque during
press-on.
Preload bearing with assembly sleeve

and steady control of the torque.
26
Rotary group assembly Motor A 6 VM Serial 63
Repair Instructions
Rotary group : mechanical part
Assemble safety ring.

Determine dimension for adjustment
disc with final dimensions (crossover).
Install adjustment disc. Assemble

safety ring. Drive shaft ready for
assembly.
27
Repair Instructions
52
53 Insert retaining plate with pistson and center pin. Use screw
with Precote-coating.
54 Make sure all parts are fitted in correctly.
55 Swivel cylinder block to max. and fix the cylinder.
28
Repair Instructions
Rotary group completely assembled

ready for assembly.
Place assembly sleeve.
Warm up housing to 80°C.
29
Repair Instructions
Insert rotary group into housing to

seat position.
Fix zero position of cylinder with

Qmax.screw.
1. Disassemble cylinder fixing screw.

2. Insert O-ring.
30
Rotary group adjustment Motor A 6 VM Serial 63
Repair Instructions
56 Determine cylinder swivel range to max. angle with screw.
57 * Disc.
58 Place centering disc.
59 Mount measuring device.
60 Check dimension X.
31
Assembly of the port plate Motor A 6 VM Serial 63
Repair Instructions
1. Assemble port plate with differential

piston.
Take care of assembly design !
Tighten fixing screws with

torque.
2. Swivel rotary group to "starting

position".
3. Set screw to dimension *
4. Assemble plug.
5. Remove assembly sleeve.
61
62 Assemble cover.
63 Assemble control components.
32
Motor assemble Motor A 6 VM Serial 63
Repair Instructions
62 Assemble shaft seal, disc and safety ring.
Press-in with assembly sleeve.
Take care of press-in depth.(see fig.15)
33
WORKING (ADJUSTING)
TRANSMISSION
75-8-M125 EN
16 / 03 / 2007
CONTENTS
- Hydrostatic Diagrams ................................................................................................................. 2à5
- Pump A4VG/DA ........................................................................................................................ 6
- Sectional view of Pump A4VG/DA ...............................................................................................................7
- Motor A6VM/DA Série 63 .................................................................................................................8 à 11
- Diagrams colour pump and motor ..............................................................................................
- Operation A4VG..DA .................................................................................................................. 16
Pilot Circuit .............................................................................................................................. 17
- Control Cartridge Operation ......................................................................................................... 18 à 19
- DR valve .................................................................................................................................. 20 à 22
- HP valve, relief valve adjustment................................................................................................ 23
- Pump Pressure Measuring Points A4VG 56 DA...........................................................................................24
- Motor Pressure Measuring Points A6VM....................................................................................... 25
- Points de réglage Transmission ................................................................................................. 26
- Transmission A4VG - A6VM (Inspection before Start-up) ................................................................. 28
- Transmission Inspection and Adjustments .................................................................................... 29 à 35
- Adjusting the Pedals and TH7 Valves............................................................................................ 36
- Hydrostatic Transmission Adjustment Sheet.................................................................................. 39
- Pressure test Kit....................................................................................................................... 40 à 41
1
MLT 742 H TURBO LSU SÉRIE 2-E2 HYDROSTATIC TRANSMISSION CIRCUIT
X1
X2
B
T1
T2
A
2
MLT 742 H TURBO LSU SÉRIE 2-E2 HYDROSTATIC TRANSMISSION CIRCUIT
X1
X2
3
4
PRF(O)
2 A B T
3 1
3 2 1
AV AR D3
3 2 1 P
R L
M1 B T U
x
BT PD 200b 200b
MH
a
200 cm3/tr
OPTION FREINAGE REMORQUE
SCFR(O) LS 140b
b
V1 V2
T P
S
x
x
ES. AV.
T G X1 X3 A
P T
ES. AR.
Y
FDAV VDAV VDAR FD VAFR(O)
N LS
PFR B
VP RLF
B2 L N
x
A
0,7 L. A B
13 b Gicleur Ø1
EVP T P
MC
FT P T P
B A
TH7
A
15 microns
absolu
X Y
a b
MB Fe Fa Fa1 PS T1
x
B
B
P 63 cm3/tr M
PH
L L1 L2 S
x
x
x
CAR CAR FR
R
N
RH 6b
M
0.5 b 2b 5b
RF
FR
BT
AC
PH
MC
MH
RLF
VPV
TH7
CAR
EVPV
10 μ 1ère monte
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
LEGEND
15 μ
RF
Level
Cooler
PCR 14 cm3/tr
I.C engine
Return filter
Accumulator
Transfer Box
Hydraulic tank
Master cylinder
Brake fluid tank

TH7 manipulator
Hydrostatic Motor
Hydrostatic pumpe
N CA
Back pressure valve

Niveau moyen :
Gear changing actuator

125 μ
104 litres
Gear changing solenoid valve

PUMP A4 VG 71 DA1 / MOTOR A6 VM 107 DA2 / 63 W
MLT 742 H TURBO LSU SÉRIE 2-E2
HYDRAULIQUE DIAGRAM
5
PUMP A 4 VG / DA
Like the A 4 V series, this pump is fitted with :

• a tachometric control device,
• a plate restoring force control device,
but also :
• a DR control known as a "flow cut-off valve" with pressure hold.
MAIN DIFFERENCES IN RELATION TO THE A 4 V SERIES :
- Less space required - 50 mm shorter.

- Booster pump built into the connection plate.
- Larger control cylinder.
- Larger drive shaft to receive greater torque.
- Straight piston pump.
- Plate angle : 18°.
- Greater speed.
- Three ports on pump housing : X1 - X2, housing pressure.
MOST IMPORTANT
A locking screw for the plate oscillation bearings is fitted to the side of the pump fixing flange.
Do not mistake this for the pressure connection plug.
6
SECTIONAL VIEW OF PUMP A 4 VG DA
7
MOTOR A 6 VM / DA
SERIAL 63
Characteristics of serial 63 in comparison with 60 :
- Crankcase in a single part (suppression of the seal support cover).

- Bearing held by retaining rings "Length reduced by approximately 11 %".
- Retainer spring of the rotor (instead of Belleville washers) increased operating safety.
- Additional sweep port at the front of the bearings.
- Cylinder head O-ring joint (instead of the gasket)
- Control piston in two parts, without seal, reinforced section, quicker tilting time, less hysteresis.
- Exchange valve (sweep) integrated into the lower cover.
Scavenging rates
Calibre 28 55 80 107 160 200 250 355 500 1000
Débit de balayage 3,5 3,5 5 8 10 10 10 16 20 25

(L/mn)
8
MOTOR A 6 VM / DA
SERIAL 63
HYDRAULIC DIAGRAM MOTOR

A 6 VM / DA SERIE 63
9
MOTOR A 6 VM / DA
SERIAL 63
CONTROL ELEMENT
1 - Housing
2 - Liner
3 - Piston
4 - Adjusting socket
5 - Spring seat
7 - Pressure spring
9 - Pressure spring
10 - Slide
12 - Union
14 - O ring joint
15 - Screw
16 - Plug
17 - Retaining ring
18 - Set screw
19 - Set screw
20 - Cylindrical pin
21 - Flanged nut
22 - Plug
23 - Plug
24 - Plug
25 - Plug
10
MOTOR A 6 VM / DA
SERIAL 63
SWEEP AND BOOST VALVE
1 - Housing
2 - Sweep slide valve
3 - Neck : pin
4 - Valve slide
5 - Plug
6 - Plug
7 - Washer
8 - Pressure spring
9 - Pressure spring
10 - Nozzle
11 - Nozzle
15 - Screw
16 - O ring joint
17 - O ring joint
18 - O ring joint
19 - Retaining ring
20 - Plug
24 - Adjusting washer
30 - Calibrated orifice
11
B
A4VG ... DAD

Baureihe/series 32
Verstellpumpe NG 71...180
A Variable pump Size 71...180
T S
Hochdruck Niederdruck Saugdruck Lecköldruck Steuerdruck Stelldruck

High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure
Haute pression Basse pression Pression d'aspiration Pression de drainage Pression de pilotage Pression de commande
Alta pressione Bassa pressione Pressione d'aspirazione Pressione di trafilamento Pressione di pilotaggio Pressione di posizionamento
Alta presión Baja presión Presión de aspiratión Presión de drenaje Presión de pilotaje Presion de taraje
Vor Festlegung Ihrer Konstruktion bitte verbindliche Einbauzeichnung anfordern - Prior to finalising your design, please obtain a certified drawing.
RDE 92003-14-L+B/07.98
15
OPERATION
OF PUMP A 4 VG..DA
PILOT CIRCUIT
The pilot circuit is drawn from the booster circuit via the control cartridge.
On leaving the control cartridge, the control flow passes through a 1.8 to 2 mm dia. jet to feed the PS outlet at the
same time as the DR valve.
The jet is located behind a plug in the pump connection plate near to the MB pressure connection port. Its role is to
prevent saturation through the TH 7 valves and the DR valve. If the jet is blocked, there is no pilot pressure to the
circuit.
The pilot flow through the hydraulic hoses is directed towards two TH 7 valves, then towards the front/rear drive
solenoid valve.
• ROLE OF THE TH 7 VALVE ON THE BRAKE
This second valve is activated by the brake pedal on the clearance stroke to cut off the pilot pressure when the
brakes are activated. This provides hydrostatic braking before the brake discs come into action.
This TH 7 valve also allows the operator to reduce or keep the same travel speed when approaching the loading
site if he wishes to increase the IC engine to a much higher speed with the accelerator in order to achieve high
lifting speed (increased delivery from main pump).
• FORWARD DRIVE /NEUTRAL /REVERSE DRIVE SOLENOID VALVE
Its function is to direct the pilot flow from one side or another of the control cylinder of the pump in order to pilot
the pump towards the forward or rear drive. Contrary to the A 4 V series, the pumps in the A 4 VG series are not
equipped with a pilot jet at X1 and X2 but the slide valve of the forward/rear drive solenoid valve is fitted with
stepping slots.
The return port located in the centre of the solenoid valve is equipped with a 0.8 mm dia. time delay jet acting on
the forward/rear drive reversal movement.
16
PILOT CIRCUIT
PUMP A 4 VG 71DA
MLT 742 H TURBO LSU SÉRIE 2-E2
Ø 1 mm dia. jet on
solenoid valve supply
To Servocontrol Cylinder
2 mm dia. jet access Ø 1.2 mm dia. jet on return

on control valve outlet
PS
To brakes
RLF
B2 L N
x
Gicleur Ø1
MC T P
TH7
A
17
CONTROL CARTRIDGE
OPERATION
The pilot pressure is drawn via the control cartridge slide valve into the booster circuit. At maximum IC engine
speed, the pilot pressure is a few bars lower than the booster pressure.
On idling (930 rpm), the booster flow which passes through the calibrated opening in the control cartridge slide
valve is insufficient to create a drop in pressure capable of displacing the slide valve 1 against the force of the
spring 2. The pilot pressure is therefore nil.
When the operator accelerates in order to move forward (to approximately 1050 rpm), the booster flow increases ;
the drop in pressure before the calibrated opening is now sufficient to move the slide valve to the left, against the
spring, thus revealing the pilot opening.
When the pilot pressure reaches approximately 6 to 7 bar, the servocontrol cylinder begins to move, tilting the plate
of the variable capacity pump. The pump begins to discharge (start of control). The greater the engine speed, the
more the booster flow increases thus leading to a rise in the pilot pressure and therefore increased influence on
the pump and greater machine speed.
To halt this process, the operator stops accelerating, the booster flow drops, the pressure drop is reduced and the
spring 2 pushes back the slide valve 1 thus closing the booster passage to the pilot conduit. The residual pilot
pressure is discharged towards the housing.
18
CONTROL CARTRIDGE
OPERATION
Variable capacity pump
Servocontrol cylinder
FWD/N/RR drive
solenoid valve
Booster
pressure
relief valve
Item 2 Item 1
Cartouche
de
régulation
Accelerator
Start of control
adjusting screw
Booster
Pump
19
DR VALVE
1) FUNCTION
To cut off flow while maintaining pressure. This corresponds to a return of the pump displacement to the “O”
before the HP valve calibration is reached.
This valve anticipates HP relief valve activation on acceleration and deceleration (rapid rise in pressure).
The peak pressure is reduced by the HP relief valves which also protect the circuit against ultra-rapid
fluctuations. The calibration range for cutting off the flow while maintaining pressure covers the whole working
pressure range. The corresponding calibration values should however be 20 to 30 bar lower than those of the
HP relief valves.
- Reduced transmission noise.

- Wider control range.
Composition of the DR Valve
1) HP circuit sensor flow selector.

2) A slide valve which connects the pilot circuit to the tank in order to release the pump from the pilot control
while maintaining the 400 bar level (control starts at 6 to 7 bar, control ends at 20 bar with maximum flow).
The DR valve allows the flow to be reduced while retaining maximum torque.
2) OPERATION
The HP MA or MB pushes the HP circuit selector upwards or downwards thus closing the opposite low pressure
port (in a HP direction of A to B, the HP traverses the centre of the selector through a small channel).
In all cases, the HP then pushes the needle 4 which in turn raises the control slide valve 3 which creates a
partial connection between the control opening and the return thus reducing the pilot pressure.
The effect of this is to reduce the pump displacement, thus reducing the flow while maintaining the 400 bar HP
(flow reduction for a maximum torque).
This action of removing the pilot control from the pump acts in the same way as the restoring forces generated
by the HP and the adjustment of the control plate.
20
SECTIONAL VIEW
OF THE DR VALVE
Locknut 14 9 Adjusting screw
Collar 8 1 End cap
Seal 10 2 Bronze slide valve
Spring 7 3 DR control slide valve
Pilot
Collar 8 4 Needle
MB 5 HP selector
MA 6 Seat
21
DR VALVE
Adjusting Screw
Pilot Needle
Hole in Collar for Leaks

Bronze Slide Valve
HP Selector
Control Slide Valve
Seat
IMPORTANT
In the event of a considerable drop in the IC engine speed, check that the pilot needle has not become stuck in the
slide valve.
22
HP VALVE
WITH HAULAGE BY-PASS
A4VG 71 - 180 DA
PRESSURE RELIEF VALVE ADJUSTMENT :
• Remove the lead seal A.

• Take off the cap B.
• Loosen the locknut D.
• Adjust the screw E to increase the pressure.
• Refit the cap having installed a new lead seal.
RELEASING THE HP RELIEF VALVES FOR HAULAGE :
• Adjust the two HP relief valves.

• Withdraw the caps B slightly without removing the lead seals A.
• Loosen the nuts C by a maximum of two turns.
Once the haulage operation is over:

• Tighten the nuts C.
• Refit the caps B.
REMARKS : Haulage should be carried out at a very low speed and over a short distance only.
C D
23
PUMP A 4 VG 71 DA
PRESSURE MEASURING POINTS
For the kits of pressure port hoses and couplings, please refer to the catalogue "pressure
gauge box" Ref. 547037.
PUMP A 4 VG 71 - 90 DA
Pilot pressure connection

(16x150) Ref. : 477 485
HP pressure connection
(12x150) Ref. : 477 484
Booster pressure connection

Branch piece Ref. : 165 711
+ connection Ref. : 58 181
Housing pressure connection
Branch piece Ref. : 173 568
+ connection Ref. : 58 181
24
PRESSURE MEASURING POINTS
MOTOR A 6 VM
MOTOR A 6 VM Serial 63
High pressure (14 x 150)
Pilot pressure (14 x 150)
Changeover
pressure
(14x150)
25
TRANSMISSION
ADJUSTMENT POINTS
PUMP A 4 VG
D.R.Valve Swashplate zero position
HP Valve
Control Valve
Start of regulation
Boost Valve
Eccentric for HP Valve

valve plate adjustement
MOTOR A 6 VM
Serial 63
Regulation
screw
Minimum displacement
stop. (Do not readjust)
Maximum
displacement stop.
(Do not readjust)
26
27
TRANSMISSION
A 4 VG - A 6 VM
CHECKS BEFORE PRESSURE TESTING
• Check the transmission oil level.
• Check there are no leaks at hoses or unions.
• Check the electrical connections at the solenoid.
• Make sure the circuit is filled with oil. In some cases the filter should be filled with oil prior installation.
• Confirm correct connection of pilot hoses :

- Port x 1 on pump to X1 on motor,
- Port x 2 on pump to X2 on motor.
• In all cases, the pilot hose be opposite the HP hose

(e.g. If the HP for forward drive is on the right of the motor the forward pilot hose must be on the left).
• Install the pressure gauges for boost, pilot, HP and housing checks.
PREPARATION
• For safety purposes support the front wheels on blocks (disconnect 4 wd shaft if applicable).
• Crank the engine a few times with the fuel shut off solenoid disconnected, to ensure the circuit is charged
with oil.
• The boost pressure during cranking should be around 14 bar.
"Never run the transmission without boost pressure".
• Reconnect the fuel shut off solenoid.
• Start the engine and run for a few minutes at idle.
• The boost pressure should be between 24 bar.
A flickering gauge indicates cavitation in the system.
With the drive selector in neutral the pressure in the two HP circuits should be the same as the boost
pressure.
• Bypass the inching valve(s) using flexible hose.
• When the oil temperature is -50 to 60 C check the engine speed :
- Idle speed,
- Maximum speed under load.
28
TRANSMISSION INSPECTION
AND ADJUSTMENTS
1. CHECK/ADJUST BOOST PRESSURE
- The pumps A 4 VG 71-180 are equipped with an adjustable boost valve.

To increase the boost pressure, tighten the screw.
29
AND ADJUSTMENTS
2. ADJUSTMENT OF SWASHPLATE "O" POSITION
- Install two 100 bar gauges at the HP test points.

- Ensure the parking brake is released, the truck supported on blocks (wheels free to turn).
- Engine running at idle.
- Drive selector in neutral position.
- Unscrew the locknut of the "O" adjuster (19 mm ring spanner). Screw in very slowly the screw (6 mm allen key)
until movement is seen on the pressure gauge.
- Make a mark relative to the allen key position, slowly turn the screw in the opposite direction until movement is
seen on the other pressure gauge, mark the position of the allen key. Turn the adjuster back so that the allen key
is exactly central between the two marks. Lock the locknut.
• CKECKING ADJUSTMENT
- Remove the low pressure gauges from the HP circuit and install two 600 bar gauges :
1) Check the start of regulation in forward and reverse drive using a tachometer.
Select forward drive, increase the engine speed slowly until the wheel begin to turn - record the engine speed.
Repeat the same in reverse drive.
Compare the two readings ; they should be identical
2) Check the pilot and HP readings.
Select forward drive, apply foot brake, accelerate progressively to maximum speed.
Record the forward HP and forward pilot pressure.
Repeat the same operation in reverse. The valves should be the same.
30
AND ADJUSTMENTS
3 A. CHECK AND ADJUST START OF REGULATION
Control valve
Start of regulation
START OF REGULATION :
• Check the engine speed at idle depending on machine type. It should be 750 to 850 rpm.
Select forward drive, gradually increase the engine speed until the wheels start to move - check the
engine speed.
It should be between 1050 and 1100 rpm. If not adjust the screw on the end of the regulation valve.
• Screw in to delay the start of regulation.
• Screw out to advance the start of regulation.
• Adjustment of the start of regulation outside its specified limits will change the performance curve of the
pump.Your must systematically check the governing end r.p.m. "400 bars for a given engine speed".
(See machine specifications).
• Confirming the adjusment is correct is done as described in step 2 point 2.
For certain machines fitted with TH7 valves on the accelerator,

please refer to specific pages and to the Service memo book.
31
AND ADJUSTMENTS
3 B. CHECK AND ADJUST END OF REGULATION
End of regulation
CHECK :
- The truck must be blocked, against a bay with a load on the fork arms for instance.
- Drive reverser in forward drive.
- Engine at low idle - check rpm.
- Gradually increase the engine speed until the forward HP reading is 410 bar.
END OF REGULATION :
- The adjustment of the pump end of regulation at 1650 rpm is obtained using an eccentric screw which restricts
the pump flow creating back pressure against the swash plate.
This adjustment can only be set using a test bench.
IMPORTANT
The slot in the eccentric screw should point towards the boost pump
(opposite to A4V pump where slot pointed to drive shaft). The
adjustment must not go beyond 90 to the left or right - Do not exceed or
damage may occur.
As for adjusting the HP, this adjustment must be done with the quick-
release valve over-calibrated.
32
AND ADJUSTMENTS
4. CHECK AND ADJUST HP VALVES
• The HP valves are checked with the truck supported on blocks with the brakes applied
• It is also necessary to by-pass the inching (TH7) valve(s) with a flexible hose.
• Also, if fitted, by-pass the parking brake drive isolation system.
• Overset the DR valve (1) to check the pressure of the

HP valves.
Screw the adjuster in 1 turn. The HP valves pressure
should be 410 bar *.
(During this test the engine speed should drop 500 -
600 rpm).
After checking the HP, set the QR valve to a lower value
which is 10% of the HP.
CALIBRATION OF HP RELIEF VALVE :
A 4 VG 71 - 180 DA series pump
• Remove the lead seal A.

• Remove the cap B.
• Loosen the locknut D.
• Turn screw E to increase the pressure.
• Refit the cap having installed a new lead seal.
C D
33
AND ADJUSTMENTS
5. ADJUSTING MOTOR A 6VM DISPLACEMENT CHANGEOVER
A) CHECK MINIMUM DISPLACEMENT (MAX. SPEED) :
• The check is made driving the truck on level ground with the engine a full speed in forward drive.
HIGH
PRESSURE REGULATION
PRESSURE
A 6 VM DA Serial 63
CHANGEOVER PRESSURE
• Connect two 600 bar pressure gauges as shown above. At maximum drive speed the two gauges should
read the same. This signifies that both sides of the Servo piston are subject to the same pressure and the
motor is at its minimum displacement.
• The actual speed can be verified (see the speed scale and technical data for the machine).
B) CHECK START OF REGULATION :
• With the wheels raised from the ground and the truck supported on blocks gradually apply the brake pedal
to raise the pressure in the HP circuits (inching valve by-passed).
• Watch the two gauges. When the HP gauge shows 200/250 bar the changeover pressure will drop then the
HP will continue to rise until it reaches the setting of the DR valve.
(Changeover pressure : See specification for different trucks).
• The changeover point can be adjusted by the screw.
34
AND ADJUSTMENTS
C) MAXIMUM DISPLACEMENT : (MAX. TRACTIVE FORCE)
• To make this adjustment, the machine should be chocked (brakes locked).

The check is made at maximum IC engine speed in forward drive.
• The switching pressure (large section side of control cylinder) must be around zero bars.
• Adjust the control screw as required (tighten to increase the switching pressure, loosen to reduce).
• A check on the tractive force (using a hook) should then be carried out (refer to “Hand book” for values).
35
ADJUSTING PEDAL AND TH7 VALVE ON
MLT 742 H Turbo LSU
3 à 4 mm
D
to 4 mm
de3pédale
C H
E I
Garde
Free play
F L
G
B J
125 mm
K
140 mm
A
PROCEDURE FOR ADJUSTMENT
A) TH7 AND BRAKE PEDAL.
- Adjust height of brake pedal Item A from cab floor to 140mm. This dimension to be measured without pedal cover
or floor covering.
- Use screw item C to adjust TH7 Item B.
- Tighten locknut Item D.
- Check adjustment of TH7 protection screw Item E, and tightness of locknut Item F.
- Place push rod Item G in contact with pedal support, and adjust master cylinder by turning push button Item H.
- Tighten locknut Item I.
- Use drive screw Item J for push rod Item G to adjust free play of brake pedal Item A to between 3 and 4mm.
- Tighten locknut Item K.
B) TRANSMISSION SHUT-DOWN SWITCH.
- Pedal at rest (touching TH7 screw Item C)

- Adjust position of switch Item L by operating transmission shut-down switch when pedal is 125 mm above cab
floor (see diagram).
36
ADJUSTING PEDAL AND TH7 VALVE ON
MT 1033 HL Turbo
PROCEDURE FOR ADJUSTMENT
A) BRAKE PEDAL.
- Use stop Item B to adjust height of brake pedal Item A D
3 à 4 mm
from cab floor to 160mm. This dimension to be C
E
measured without pedal cover or floor covering.
3 ‡ 4 mm
B
pédale
- Tighten locknut Item C.
pÈdale
- Turn follower Item D to adjust free play for brake pedal
Garde dede
Item A to 3 to 4 mm.
Garde
- Tighten locknut Item E. F
G A
B) ADJUSTING TH7 VALVE
160
- Pedal at rest (touching stop Item B)
- Put a 0.5mm-1.0mm spacer between screw head Item
F and TH7 push button.
- Adjust position of stop Item F.
- Tighten locknut Item G.
PROCEDURE FOR ADJUSTING BRAKE AND ACCELERATOR PEDAL CONTACTORS

- The accelerator pedal contactor should change the idling speed to 950 +/- 50 rpm (essential before hydrostatic
pump regulation starts at 1150 +/- 50 rpm).
The brake pedal contactor should change the idling speed after release of TH7 push-rod, that is, before any braking
of the machine.
NOTE: - It is only possible to change speed when reverse gearstick is in neutral and when machine is practically
stopped (brake pedal pushed down).
- In large displacement mode the engine is blocked at low “snail” speed, thus limiting travel speed. The limit on
speed is possible whatever the speed selected - whether hare or tortoise - but only in forward gears
37
38
MANITOU - HYDROSTATIC TRANSMISSION CHECK SHEET - A4VG--DA / A6VM--DA
DATE OF CHECK : TYPE OF MACHINE : PUMP TYPE :
NAME OF DEALER : SERIAL NO : SERIAL NO :
NAME OF ENGINEER : HOURS RUN : MOTOR TYPE :
SERIAL NO :
IC ENGINE SPEED IN RPM:

1 idle : ......... 2 max speed : .......... 3 max with hydraulics blocked : ......... 4 start of regulation : ......... 5 end of regulation 400 b :.......... 6 max fwd drive blocked............
HYDROSTATIC PUMP HYDROSTATIC MOTOR

STATE OF DRIVE LEVER ENGINE BOOST PILOTE HIGH PRESSURE CASE SUCTION MACHINE HIGH CONTROL
MACHINE / POSITION SPEED PRESSURE PRESSURE PRESSURE VACUUM CONDITION+ PRESSURE PISTON
CONTROLS FWD REV FWD REV DRIVE LEVER PRESSURE
POSITION
BOOST VALVE IDLE

ADJUSTEMENT NEUTRAL Max FWD
MAX drive speed
Start of regulation
AT MAX SPEED FWD
CONTROL CARTRIDGE MAX
ADJUSTMENT FWD drive
Start of regulation at point of
REV
MAX displacement
change over
BLOCKED FWD MAX

CHECK HP
VALVE
(DR. VALVE OVERSET) REV MAX FWD drive
blocked
End of max speed
FWD regulation
BLOCKED
END OF REGULATION End of
CHECK REV
regulation OIL TYPE:
FWD OIL TEMPERATURE : ..............................°C
BLOCKED MAX
DR VALVE
REV
ADJUSTEMENT MAX
TRAVEL SPEED (MAX) :
BLOCKED ..................Km / H
FWD
INCHING VALVE MAX
ADJUSTMENT
39
DRAWBAR PULL : ..................................Kg
COFFRET DE BASE - BASISKOFFER
COFRECILLO DE BASE - BASIS BOX
1
Standard - Standard
Estándar - Standard
2 3 4 4 5 6 6
7 7 7 7
Maniscopic
8 8
Kit HYDROMATIK - 2ème MONTAGE - Pompe A 4 VG - DA / Moteur A 6 VM - DA

HYDROMATIK kit - 2te MONTAGE - Pumpe A 4 VG - DA / Motor A 6 VM - DA
Kit HYDROMATIK - 2do MONTAJE - Bomba A 4 VG - DA / Motor A 6 VM - DA
HYDROMATIK kit - 2nd MOUNTING - Pump A 4 VG - DA / Motor A 6 VM - DA
49 49 49 51 51 51 51 51 52
8x100
12x150 54 14x150
53-1 55 55 48
53 53 30x200
50 50 50 50 50 50 14x150
16x150 18x150 Ø20 (S) Ø8 (L)
Flexible (By-pass valve TH7) - Schlauch (TH7 ventil by-pass) Raccord (Union flexible valve TH7)
Flexible (By-pass valvula TH7) - Hose (TH7 by-pass valve) Verschraubung (Verbindung schlauch ventil TH7)
Racor (Unión flexible valvula TH7)
50 Connection (Connection hoses TH7 valve)
4x1
56 1
57
14x150
14x150
14
x1
50
40
REP NUMERO DESIGNATION QTE
Hinw TEIL-NR BEZEICHNUNG Menge
Fig NUMERO DESCRIPCION Cant
Item PART-NR DESCRIPTION QTY
1 549 671 Coffret de base - Basiskoffer - Cofrecillo de base - Basis box 1
2 549 882 Manomètre 1/9 bar - Manometer - Manometro - Gauge 1
7 549 887 Flexible - Schlauch - Tubo flexible - Hose 4
8 549 888 Flexible pour MANISCOPIC - Schlauch für MANISCOPIC 2

Tubo flexible para MANISCOPIC - Hose for MANISCOPIC
9 549 889 Prise de manomètre - Manometer schaltung 7

Toma de manometro - Gauge connector
48 209 572 Kit HYDROMATIK - HYDROMATIK kit 1

Kit HYDROMATIK - HYDROMATIK kit
49 58 181 Prise de manomètre 8 x 100 - Manometer schaltung 3
50 58 197 Joint torique Ø 8 - "O" ring - Junta torica - "O" ring 6
53-1 199 175 Prise de manomètre 18 x 150 - Manometer schaltung 1
54 173 568 Raccord Ø 20 - Verschraubung - Racor - Connection 1
55 165 711 Raccord 8 x 100 - Verschraubung - Racor - Connection 2
By-pass valve TH7

56 191 000 Flexible 1
57 491 632 Raccord (M 14 x 150) - Verschraubung - Racor - Connection 1
41
42
GROUP 80
ELECTRICITY
ELECTRIC DIAGRAM
80-6-243630 EN
25 / 01 / 2007
CONTENTS
– ELECTRIC DIAGRAM
MLT 742 H Turbo LSU Série 2-E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3
ELECTRIC DIAGRAM MLT 742 H TURBO LSU SÉRIE 2-E2
ELECTRIC PRINCIPLE CIRCUIT 69 - Front working headlight (option)

1 - Power fuses 70 - Engine water temperature module lighting
2 - Preheating relay 71 - Fuel level module lighting
3 - Starter 72 - Hourmeter / rev counter module lighting
4 - Battery 73 - Position light indicator light
5 - Joystick power-supply cut-off 74 - R.H. rear position light
6 - Engine water temperature 75 - Ventilation switch lighting
7 - Fuel level 76 - R.H. front position light
8 - Alternator 77 - L.H. rear position light
9 - Hourmeter / rev counter 78 - L.H. front position light
10 - Indicator light module relay 79 - L.H. front low beam
11 - Battery loading 80 - R.H. front low beam
12 - Engine oil pressure 81 - Low beam indicator light
13 - Brake fluid 82 - L.H. rear fog light
14 - Hydraulic return air/oil filter clogging 83 - R.H. rear fog light
15 - Engine water temperature 84 - L.H. front main beam
16 - Free 85 - R.H. front main beam
17 - Free 86 - Main beam indicator light
18 - Handbrake 87 - Free
19 - Rear working tail light (option) 89 - Free
20 - Cab rear windscreen wiper 90 - Electronic control unit
21 - Cab roof windscreen wiper (option) 91 - Hydraulic pump electroproportional electrovalve
22 - Cold start 92 - Speed sensor ou info W alternator
23 - Engine stop electrovalve 93 - Potentiometer accelerator on injection pump
24 - Revolving light 94 - Diagnostic socket and pump data entry
25 - Front wheels alignment detector 96 - Joystick power supply cut-off relay
26 - Rear wheels alignment detector 97 - Jib head electrovalve control (option)
27 - Moving speed limitation electrovalve 98 - Transmission cut-off control on joystick
28 - Hydraulic motor rotation electrovalve 99 - Attachment electroproportional control
29 - L.H. rear reverse light 100 - Telescope electroproportional control
30 - R.H. rear reverse light
31 - Reverse sound alarm (option) COLOUR CODING
32 - Forward electrovalve bc : white bl : blue g : grey j : yellow
33 - Reverse electrovalve jvt : yellow/green m : brown n : black o : orange
34 - Low speed indicator light r : red ro : pink vt : green v : purple
35 - High speed indicator light
36 - High speed electrovalve CONECTOR
37 - High speed control relay A - Fuse box / relay (13 pin connection)
38 - Low speed control relay B - Fuse box / relay (13 pin connection)
39 - Start safety relay C - Fuse box / relay (13 pin connection)
40 - Forward relay D - Fuse box / relay (6 pin connection
41 - Reverse relay E - Fuse box / relay (8 pin connection)
42 - Reverse light relay F - Fuse box / relay (8 pin connection)
43 - Transmission cut-off relay G - Fuse box / relay (21 pin connection)
44 - Autoradio (option) H - Fuse box / relay (5 pin connection)
45 - Overload safety system I - Fuse box / relay (7 pin connection)
46 - Hydraulic movements cut-off (option) J - Fuse box / relay (8 + 2 pin connection)
47 - Sound alarm L - Prearranged relay K0 (Option)
48 - L.H. stoplight M - Prearranged (8 + 1 pin connection) (option)
49 - R.H. stoplight N - Engine box
50 - Free O - Prearranged rear (8 pin connection) (Option)
51 - Blinking center / warning P - Comodo
52 - Blinking center / warning indicator light Q - Heating ventilation
53 - R.H. rear indicador R - Air conditionning (Option)
54 - R.H. front indicador S - Cab
55 - L.H. rear indicador T - Front windscreen wiper
56 - L.H. front indicador U - Overload strain gauge
57 - Warning / indicator light switch V - Diagnostic socket
58 - Roof light AA - Attachment hydraulic locking (option)
59 - Ventilation AB - TUV adaptation
60 - Air conditionning (option)
61 - Cigar lighter ELECTRIC COMPONENTS
62 - Free A1 - Electronic control unit
63 - Free A2 - Electroproportional joystick
65 - Rear desfrosting (option) E1 - R.H. rear indicador
66 - Free E2 - R.H. front indicador
67 - Front windscreen washer E3 - L.H. rear indicador
68 - Front windscreen wiper E4 - L.H. front indicador
4
E5 - L.H. stoplight H6 - Warning / blinker indicator light

E6 - R.H. stoplight H7 - Position light indicator light
E7 - R.H. rear position light H8 - Free
E8 - R.H. front position light H9 - Main beam indicator light
E9 - L.H. rear position light H10 - Warning indicator light
E10 - L.H. front position light H11 - Front wheels alignment indicator light
E11 - L.H. front low beam H12 - Free
E12 - R.H. front low beam H13 - Brake indicator light
E13 - L.H. front main beam H14 - Rear wheels alignment indicator light
E14 - R.H. front main beam H15 - Hourmeter / rev counter module indicator light
E15 - R.H. rear working tail light (option) H16 - Engine water temperature module indicator light
E16 - L.H. rear working tail light (option) H17 - Fuel level module indicator light
E17 - L.H. front working headlight (option) H18 - Low beam indicator light
E18 - R.H. front working headlight (option) H19 - Ventilation indicator light
E19 - Revolving light H20 - Low speed indicator light
E20 - L.H. reverse light H21 - High speed indicator light
E21 - Roof light
E22 - R.H. reverse light (option) K0 - Air-conditionning relay (option)
E23 - L.H. rear fog light K1 - Transmission cut-off module : joystick
E24 - R.H. rear fog light K2 - Transmission cut-off relay
K3 - Reverse relay
FUSES K4 - Forward relay
F1 - ECU power supply (7.5A) K5 - Buzzer
F2 - Rear working tail light (option) (15A) K6 - Free (EVTDF option)
F3 - Rear / roof windscreen wiper (7.5A) K7 - Hydraulic movements cut-off (option)
F4 - Engine stop electrovalve (10A) K8 - Start safety relay
F5 - Revolving light (7.5A) K9 - Warning / blinking center
F6 - Wheels alignment (5A) K10 - Overload safety module
F7 - Load status indicator device (10A) K11 - Reverse light relay and buzzer/direction of rotation
F8 - Forward / Reverse / Neutral transmission (15A) of hydraulic motor
F9 - Fault sound alarm light (5A) K12 - Free
F10 - Sound alarm / stop switch (15A) K13 - Low speed relay
F11 - Free (15A max) K14 - High speed relay
F12 - Indicador powers supply (10A) K15 - Joystick power supply cut-off relay
F13 - Ventilation (30A) K16 - Preheating relay
F14 - Cigar lighter socket (10A) K17 - Indicator light module relay
F15 - Free (25A max) K18 - Transmission cut-off module
F16 - Air conditionning (option) (10A max)
F17 - Free (15A max) M1 - Starter
F18 - Front working headlight (option) (15A) M2 - Front windscreen wiper
F19 - Rear desfrosting (option) (15A max) M3 - Windscreen washer
F20 - Free (10A max) M4 - Roof windscreen wiper (option)
F21 - Front windscreen wiper and windscreen washer (10A) M5 - Horn
F22 - Free (15A max) M6 - Ventilation
F23 - R.H. sidelights + Control panel lighting (7.5A) M7 - Reverse sound alarm (option)
F24 - L.H. sidelights (7.5A) M8 - Rear windscreen wiper
F25 - R.H. indicadors (7.5A) M9 - Fuel pump
F26 - L.H. indicadors (7.5A)
F27 - Low beam (15A) P1 - Hourmeter / rev counter module
F28 - Main beam (15A) P2 - Fuel level module
F29 - Warning + roof light (15A) P3 - Engine water temperature module
F30 - Lighting switch, horn and indicadors (25A)
F31 - Starter (20A) R1 - Preheating resistor
F32 - Electroproportional module (3A) R2 - Fuel sensor
F33 - Diagnosic socket (1A) R3 - Engine water temperature sensor
F40 - Equipments (40A) R4 - Rear desfrosting resistor (option)
F41 - Equipments (40A) R5 - Accelerator potentiometer of fuel injection pump
F42 - Preheating (80A) R6 - Proportionnal modulus resistance of attachment
F43 - Alternator (80A) R7 - Proportionnal modulus resistance of telescope
R8 - Cigar lighter resistor
G1 - Battery
G2 - Alternator S1 - Key switch
S2 - Forward reverser
H1 - Battery load indicator light S3 - Engine oil pressure switch
H2 - Engine oil pressure indicator light S4 - Braking fluid
H3 - Brake fluid indicator light S5 - Air filter clogging
H4 - Air/oil hydraulic return filter clogging indicator light S6 - Front wheels alignment sensor
H5 - Engine water temperature indicator light S7 - Brake switch
5
S8 - Front windscreen wiper / windscreen washer switch

S9 - Sound alarm control
S10 - Wheels alignment switch
S11 - Warning switch
S13a - Position light (comodo)
S13b - Low / main beam (comodo)
S13c - Indicadors (comodo)
S15 - Rear working tail light switch (option)
S16 - Stoplight switch
S18 - Front working headlight switch (option)
S19 - Revolving light switch
S20 - Rear / roof windscreen wiper switch
S21 - Ventilation switch
S22 - Overload strain gauge
S23 - Hydraulic return filter clogging
S24 - Speed selector switch (high speed / low speed)
S25 - Transmission cut-off switch to accelerator pedal
S26 - Moving speed limitation switch
S27 - Rear wheels alignment sensor
S28 - Rear desfrosting switch (option)
S29 - Rear fog light switch (option)
S30 - Switch on brake pedal
S31 - Cold start switch
S32 - Switch of joystick transmission cut-off
S33 - Switch of jib head electrovalve control (option)
S40 - Cigar lighter temporised switch
S41 - Seat sensor
V1 - Fault test diode

V2 - Diode (TUV)
Y1 - Engine stop electrovalve

Y2 - Forward electrovalve
Y3 - Reverse electrovalve
Y4 - Cold start electrovalve
Y6 - High speed electrovalve
Y7 - Moving speed limitation electrovalve
Y8 - Hydraulic engine rotation electrovalve
Y9 - Hydraulic pump proportional electrovalve
Y10 - Telescope proportional electrovalve
Y11 - Attachment proportional electrovalve
6
ELECTRIC DIAGRAM MLT 742 H TURBO LSU SERIE 2-E2
S1 F9 E F2 F3 F4 F5 F6 F8
r
J J J r
J A A A B B
I I I OP K5 E r
J J
30 30 17 17 50 19 19 54 15 58
r r r r
m ro o r r H r S2
H1 H2 H3 H4 H5 H8 H12 H13 r S15 S20 r S19 r S10 j S25
vi B B B F E F E E F E E K11 K2 K14 K18
or AV N AR m
J J J J B B
F31 H H S30
N N bl g o n vt v
or n r j
B B K1
NN m n jvt bc vt o vt ro bl j g jvt g jvt m
V1 V1 V1 V1 V1 V1 V1 V1 or B
S26 S24
ro
F40 F41 K8 I B I I I I I
K4 K3 K13
B B
N N N L R m n
N n V1 g o n g vt 3,5s n
F42 F43 M1 V1 V1 V1 V1 V1
R3 R2 S S S S S S N M S H H S7 S41
B ro r r
n bc
G1
K16 ro r m r bc bl bl bl bl P bc vt o vt ro bl jvt j j J g m n m n m n or or bl ro or m r or jvt m m jvt n
NN P N P S7
N G N N S3 S4 S5 S23 T n
N N r/n
K17 S31 jvt
jvt jvt G2 P1 K17 Connection A1/B4 secteur 92
jvt r/n
R1 R1 R1 R1 K16 K15 P3 P2 jvt
E15 E16 M8 jvt
M4 Y4 Y1 M9 E19 S6 H11 S27 H14 Y7 Y8 E20 E22 M7 Y2 Y3 H20 H21 Y6 K14 K13 K8 K4 K3 K11 K2
jvt
J F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
J J
j
j
r
P F30
F7 F10 F11 P S13c F29 F12 F13 F16 F14 F15 F17 F19 F20 F21 F18 o F22
S13a S13b J
m o J r D v m m
H S22 G G B B A B A
vt vt r r
j m P P G L r vt P P P
Q S21 r S28 r o
M S11 S18
K7 S16 A ro ro ro bl j A bc G B
o m g n K0
S9 n G r o V2 r K6
m bc vt j g r vt r Q G Q D D D D D D m bl r
G M O g S8 V2 S29
F25 F26 v r ro vt o GG
S M F23 F24 F27 F28
g n R bl vi
RR L L Tempo
UUUUUU C C C C A D S40 J J
H G I K9 S Q L T T T S C C C C C C C F C C F J
E O O
r g J v bl n n vt r r jvt ro g g n n r j m m jvt n vt jvt ro r jvt m bl bl bl bl bl bl j j j jvt r bc bc bc j
G F O Q O G
K10 K7 M5 E5 E6 H6 E1 E2 E3 E4 H10 E21 M6 K0 R8 R4 M3 M2 E17 E18 H16 H17 H15 H7 E7 H19 E8 E9 E10 E11 E12 H18 E23 E24 E13 E14 H9 K6
jvt jvt
jvt
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 89
F1 F32 K15 AB
j bl
G j
vi F33
M r r V r
V
V A2
V R6
V S33 9 S32 7 R7
Connection P1 secteur 9
V
r r r r/n n vt o vi
A1 10 8 6 4 5 3 1 2
41 42 33 17 51 50 52
o bc j jvt n m jvt
1 27 31 47 46 49 2
r r m vt r j jvt jvt
G AA
bl
r bl
R5
Y9 K1 Y11 Y10
90 91 92 93 94 96 97 98 99 100
7
ELECTRIC DIAGRAM
80-6-268680 EN
15 / 11 / 2007
80-6-268680EN 2 15/11/2007
CONTENTS
-ELECTRIC DIAGRAM
MLT 742 H Turbo LSU Série 3-E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15/11/2007 3 70-6-268680EN
ÉLECTRIC DIAGRAM MLT 742 H TURBO LSU SÉRIE 3-E2
PRINCIPLE ELECTRIC CIRCUIT 57 - R.H. front indicator

58 - L.H. rear indicator
1 - Power fuse 59 - L.H. front indicator
2 - Starting safety relay 60 - Warning unit / indicator light switch
3 - Preheating relay 61 - Roof light
4 - Starter 62 - Clock
5 - Battery 63 - Ventilation
6 - Electroproportional joystick power supply cut- 64 - Air conditioning (Option)
off 65 - Free
7 - Water temperature Indicator 66 - Free
8 - Fuel level Indicator 67 - Free
9 - Brake oil pressure 68 - Pneumatic seat (Option)
10 - Alternator 69 - Rear defrosting
11 - Hourmeter 70 - Work headlight on jib (Option)
12 - Indicator light module relay 71 - Front working headlight (Option)
13 - Load battery indicator 72 - Working tail light (Option)
14 - Engine oil pressure 73 - Clock indicator light
15 - Brake fluid 74 - Fuel level module lighting
16 - Air / hydraulic filter clogging 75 - Water temperature module lighting
17 - Engine water temperature 76 - Hourmeter module lighting
18 - Free 77 - Position indicator light
19 - Free 78 - Rear right position light
20 - Hand brake 79 - Plate light (Option)
21 - Electronic control unit 80 - Ventilator switch lighting
22 - Hydraulic pump electroproportional 81 - Front right position light
electrovalve 82 - Rear left position light
23 - Speed switch or W Alternator info 83 - Front left position light
24 - Accelerator potentiometer of fuel injection 84 - L.H. front low beam
pump 85 - R.H. front low beam
25 - Pump data input and diagnostic socket 86 - Low beam indicator light
26 - Speed limitation electrovalve (Snail) 87 - L.H. rear fog light (Option)
27 - Hydraulic motor rotation direction electrovalve 88 - R.H. rear fog light (Option)
28 - L.H. rear reverse light (Option) 89 - L.H. front main beam
29 - R.H. rear reverse light (Option) 90 - R.H. front main beam
30 - Reverse gear sound alarm (Option) 91 - Main beam indicator light
31 - Forward electrovalve 92 - Free
32 - Reverse electrovalve 93 - Front windscreen washer
33 - Low speed light (Tortoise) 94 - Front windscreen wiper
34 - High speed light (Hare) 95 - Rear windscreen wiper
35 - High speed electrovalve 96 - Roof windscreen wiper
36 - High speed control relay 97 - Side windscreen wiper
37 - Low speed control relay 98 - Revolving light
38 - Starting safety relay 99 - Cold start-up
39 - Transmission cut-off relay 100 - Engine stop
40 - Reverse light relay 101 - Front wheels alignment detector
41 - Reverse relay 102 - Rear wheels alignment detector
42 - Forward relay 103 - Free
43 - Joystick JSM 104 - Autoradio (Option)
44 - Telescope electroproportional control
45 - Attachment electroproportional control
46 - Control of joystick transmission cut-off COLOUR CODING
47 - Overload safety system bc : White bl : Blue g : Grey
48 - Movements cut-off (Option) j : Yellow jvt : Yellow/Green m : Brown
49 - Hydraulic movements neutraiser electovalve n : Black o : Orange r : Red
(Option) ro : Pink vt : Green v : Purple
50 - Hydraulic movement neutraliser switch (Option)
51 - Sound alarm
52 - L.H. stoplight
53 - R.H. stoplight
54 - Flasher unit / warning unit
55 - Flashing light / warning unit indicator light
56 - R.H. rear indicator
80-6-268680EN 4 15/11/2007
CONNECTOR E25 - Left work headlight on jib (Option)

E26 - Right work headlight on jib (Option)
A - Fuses box / relay (13 pin connection) E27 - Number plate lighting (Option)
AA - Autoradio
AB - Screenwiper switch connector (9 ways + 2
ways) FUSES
B - Fuses box / relay (13 pin connection)
C - Fuses box / relay (13 pin connection) F1 - power supply ECU (7,5A)
D - Fuses box / relay (6 pin connection) F2 - Working tail light (Option) (15A)
E - Fuses box / relay (8 pin connection) F3 - Rear windscreen wiper/roof windscreen wiper
F - Fuses box / relay (8 pin connection) (7,5A)
G - Fuses box / relay (21 pin connection) F4 - Engine stop electrovalve (10A)
H - Fuses box / relay (5 pin connection) F5 - Revolving light (7.5A)
I - Fuses box / relay (7 pin connection) F6 - Wheels alignment (5A)
J - Fuses box / relay (8 pin connection + 2 pin F7 - Load status indicator device (10A)
connection) F8 - Gear reverser transmission cut-off (15A)
L - Prearranged option relay K0 F9 - Fault sound alarm light (5A)
M - Prearranged option (8 pin connection + 1 pin F10 - Sound alarm/Stop switch (15A)
connection) F11 - Work headlight on jib (15A)
N - Engine box F12 - Indicator power supply (10A)
O - Prearranged option rear (Connection 8 pin) F13 - Ventilation (30A)
P - Light switch, Sound alarm and Indicator F14 - Free (25A Maxi)
Q - Heating ventilation F15 - Free (25A Maxi)
R - Air conditioning (Option) F16 - Air conditioning (Option) (7,5A)
S - Cab F17 - Free (15A)
T - Front windscreen wiper F18 - Front working headlight (Option) (15A)
U - Strain gauge F19 - Rear defrosting (Option) (15A)
V - Diagnostic connector F20 - Pneumatic seat (10A)
X - Adaptation TUV F21 - Front windscreen wiper and Windscreen
Z - Connection 16 pin (PCB Control panel) washer(10A)
F22 - Free (15A)
F23 - Right position light + Control instruments panel
ELECTRICS COMPONENTS light (7.5A)
F24 - Left position light (7.5A)
A1 - Electronic control unit F25 - R.H. indicators (7.5A)
A2 - Electroproportional joystick F26 - L.H. indicators (7.5A)
A3 - Autoradio F27 - Low beam(15A)
F28 - Main beam (15A)
E1 - R.H. rear indicator F29 - Warning unit + roof light (15A)
E2 - R.H. front indicator F30 - Light switch, Sound alarm et indicators (25A)
E3 - L.H. rear indicator F31 - Starter (20A)
E4 - L.H. front indicator F32 - Electroproportional module (3A)
E5 - L.H. stoplight F33 - Diagnostic connector (1A)
E6 - R.H. stoplight F40 - Equipments (40A)
E7 - Rear right position light F41 - Equipments (40A)
E8 - Front right position light F42 - Engine preheating (80A)
E9 - Rear left position light F43 - Alternator (80A)
E10 - Front left position light
E11 - L.H. front low beam G1 - Battery
E12 - R.H. front low beam G2 - Alternator
E13 - L.H. front main beam
E14 - R.H. front main beam H10 - Warning unit indicator light
E15 - R.H. working tail light (Option) H11 - Front wheels alignment indicator light
E16 - L.H. working tail light (Option) H14 - Rear wheels alignment indicator ligh
E17 - L.H. front working headlight (Option) H15 - Hourmeter module indicator light
E18 - R.H. front working headlight (Option) H16 - Engine water temperature module indicator
E19 - Revolving light light
E20 - L.H. rear reverse light (Option) H17 - Fuel level module indicator light
E21 - Roof light H19 - Ventilation indicator light
E22 - R.H. rear reverse light (Option) H20 - Low speed light (Tortoise)
E23 - L.H. rear fog light H21 - High speed light (Hare)
E24 - R.H. rear fog light H22 - Clock light
15/11/2007 5 70-6-268680EN
S1 - Key switch
S2 - Gear reverser
K0 - Air conditioning relay (Option) S3 - Engine oil pressure switch
K1 - Transmission cut-off relay to hydraulic controls S4 - Brake fluid
lever S5 - Air filter clogging
K2 - Transmission cut-off relay S6 - Front wheels alignment switch
K3 - Reverse relay S7 - Brake switch
K4 - Forward relay S8 - Windscreen wiper / front windscreen washer
K5 - Buzzer switch
K6 - Free (Option EVT DF) S9 - Sound alarm control
K7 - Hydraulics movements cut-off (Option) S10 - Wheels alignment switch
K8 - Starting safety relay S11 - Warning unit switch
K9 - Warning centre / blinker S13a - Position light switch
K10 - Overload safety module S13b - low beam / main beam switch
K11 - Reverse light and sound alarm/motor rotation S13c - indicator switch
direction relay S15 - Front / back working headlight switch (Option)
K13 - Low speed relay (Tortoise) S16 - Stop switch
K14 - High speed relay (Hare) S18 - Work headlight on jib switch (Option)
K15 - Proportional joystick supply cut-off relay S19 - Revolving light switch
K16 - Preheating relay S20 - Rear / roof windscreen wiper switch
K17 - Indicator light module relay S21 - Ventilation switch
K18 - Transmission cut-off module S22 - Overload strain gauge
S24 - High/low speed selection switch (hare/tor-
M1 - Starter toise)
M2 - Front windscreen wiper S25 - Transmission cut-off switch on brake pedal
M3 - Windscreen washer S26 - Transmission cut-off selection switch on
M4 - Roof windscreen wiper (Option) accelerator pedal
M5 - Sound alarm S27 - Rear wheels alignment switch
M6 - Ventilation S28 - Rear defrosting switch (Option)
M7 - Reverse gear sound alarm (Option) S29 - Rear fog light switch
M8 - Rear windscreen wiper S30 - Switch on brake peldal
M9 - Fuel pump S31 - Cold start-up switch
M10 - Side windscreen wiper S32 - Transmission cut-off gear lever switch
M11 - Pneumatic seat compressor S39 - Pneumatic seat switch
S41 - Seat switch
S42 - Hydraulic movement neutraliser switch (Option)
P1 - Hourmeter module
P2 - Fuel level module
P3 - Engine water temperature module V1 - Diode
V2 - Diode (TUV)
V3 - Battery load indicator light diode
R1 - Preheating resistor V4 - Engine oil pressure indicator light diode
R2 - Fuel sensor V5 - Engine water temperature indicator light diode
R3 - Engine water temperature sensor V6 - Air filter / hydraulic return filter clogging
R5 - Accelerator potentiometer of fuel injection indicator light diode
pump V7 - Transmission oil pressure indicator light diode
R6 - Proportionnal modulus resistance of V8 - Transmission oil temperature indicator light
attachment diode
R7 - Proportionnal modulus resistance of telescope V9 - Brake fluid indicator light diode
V10 - Brake indicator light diode
V11 - Flashing lights / warning unit indicator light
diode
V12 - Position indicator light diode
V13 - Low beam indicator light diode
V14 - Main beam indicator light diode
V15 - Fault direction light diode

80-6-268680EN 6 15/11/2007
Y4 - Cold start-up electrovalve
Y6 - high speed electrovalve
Y7 - Max speed limit electrovalve (Snail)
Y8 - Hydraulic motor rotation direction electrovalve
Y9 - Hydraulic pump of proportional electrovalve
Y11 - Attachment of proportional electrovalve
Y10 - Telescop of proportional electrovalve
Y14 - Hydraulic movement neutraliser electrovalve
15/11/2007 7 70-6-268680EN
80-6-268680EN 8 15/11/2007
Fus.Therm.
S1 F1
F9 2A E Z
r
J J J J G
vi
I I I OP
E Z F33
30 30 17 17 50 19 19 54 15 58 K5 M r r V r H r
J J r r r r
V3 V4 V9 V6 V5 V8 V7 V10 V
Z Z Z Z Z Z Z Z V K11 K2 K14
vi B B B V
J J J J or F E F E E F E E V
N F31 H H S30
N N N bl g o n vt v V
or n r j
N Z V1 V1 V1 V1 V1 V1 V1 V1
m n or
B r r r r/n n vt o vi S26 S24
F40 F41 I B I I I I I A1
K8 K4 K3 K13
N N N
41 42 33 17 51 50 52 L R
V1 3,5s
B n g o n g vt n V
F42 F43 M1 V1 V1 V1 V1 V1
N R3 R2 V15 B 1 27 31 47 46 49 2 H H
n bc G1 Z ro V
K16 ro r m r bc bl bl bl bl P r r m vt r j jvt jvt m n or or bl ro or m r or jvt m m H
N P N P S7
N G N N N S3 S4 S5 S23
N N P r/n P1 K17
jvt jvt S30 G2 K17 R5 jvt
jvt r/n
R1 R1 R1 R1 K16 K15 P3 P2 Y9 Y7 Y8 E20 E22 M7 Y2 Y3 H20 H21 Y6 K14 K13 K8
jvt
J F jvt
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
J J
j
j
r
F8 F32 F7 F10 P F29 F12 F13 F16 F14 F15 F17 F20 F19
S13c
r
K15 G G P B
m o J r D v m m
A A A
H S22
S25 vt r S SWF 521 008
r j vt P P Q S21 A G L +
m
S9 S11
SWF 596 390
V S28
S2 j K7 M S16 o m g n K0 5 9
K1 R7 R6 r
1 0 1 10
R F S42 vt n G
K18 m bc vt j g r r D Q G Q D D D D D D M
B4 B2 PCB G P O g
V A v r ro vt o
B5
B1
A2 F25 F26
B3 L
g n R R L R
V V V V V V V E21
B7 m U U U U U U C C C C S39
n B6
I K9 Q L
V V V V V V V S32 G Dégivrage
S7 S41 E O O vitre ar
n H H r g J v bl n n vt r r jvt ro g g n n r m m
r r X
jvt ro n G v jvt Z
r bl V11 S N G M
jvt
Z S S
K2 K11 K3 K4 Y10 Y11 K1 K10 K7 Y14 M5 E5 E6 E1 E2 E3 E4 H10 M6 K0 M11
jvt jvt
jvt
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69
P F30
F11 F18 F2 o F22 F3 F21 F5 F4 F6
S13a S13b J
B A A AA
A B A A B B
S S S r
r
P P P
SWF 521 054 AB S r
+
AB AB AB S10
EG Latéral
SWF 596 151 bl j bc SWF 521 005
A B G
EG Toitl
+
5 6 9 S18 3 4 9
SWF 521 243
+ SWF 596 628 AA
S8 AB SWF 596 307
AA
1 0
1 7 2 8 10 1 72 8 10 S15 r 1 02 3 K6
SWF 521 110
20 1
bl
V2 01 0 74 8 9 5 9
j g jvt m + +
r R
+
SWF 596 473 S V2 S29 F 1 52 6 10
1 01 10
V2 F23 F24 F27 F28 S20 S19 G G -L
A3 AA
bl vi
S
AB AB
C AB S AB J J
C C C C C C F C C F AB N M J
E17 E18 E15 E16 E19
E25 E26 T T T
bl bl bl bl bl bl j j j jvt r bc bc bc T2 S M4 2 M10 j j j m n m n j
AA AA
4
raz
2 vit 1 S raz
4 2 vit 1
raz
4 vit 1 raz
4 2 2 vit 1
Z O Q Z Z +perm
M
+perm
M AR
+perm
M TOIT
+perm
M LAT
T
V12 O V13
3 - 3 - 3 - 3 - G
S S S S V14 M2 AV 1
M8 1 1 1
S31
M3 T
Z S S
Z Z
H22 H17 H16 H15 E7 E27 H19 E8 E9 E10 E11 E12 E23 E24 E13 E14 Y4 Y1 M9 S6 H11 S27 H14 K6
70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104
15/11/2007 9 80-6-268680EN
80-6-268680EN 10 15/11/2007
ELECTRIC DIAGRAM
80-6-243631 EN
06 / 02 / 2007
CONTENTS
– ELECTRIC DIAGRAM
MT 1033 HL Turbo Série 2-E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3
ELECTRIC DIAGRAM MT 1033 HL TURBO SÉRIE 2-E2
ELECTRIC PRINCIPLE CIRCUIT 68 - Front windscreen wiper

1 - Power fuses 69 - Free
2 - Preheating relay 70 - Front working headlight (option)
3 - Starter 71 - Engine water temperature module lighting
4 - Battery 72 - Fuel level module lighting
5 - Engine water temperature 73 - Hourmeter module lighting
6 - Fuel level 74 - Position light indicator light
7 - Alternator 75 - R.H. rear position light
8 - Hourmeter / rev counter 76 - Ventilation contactor lighting
9 - Indicator light module relay 77 - R.H. front position light
10 - Load indicador 78 - L.H. rear position light
11 - Engine oil pressure 79 - L.H. front position light
12 - Brake fluid 80 - L.H. front low beam
13 - Hydraulic return air/oil filter clogging 81 - R.H. front low beam
14 - Engine water temperature 82 - Low beam indicator light
15 - Free 83 - L.H. rear fog light (option)
16 - Transmission oil pressure 84 - R.H. rear fog light (option)
17 - Handbrake 85 - L.H. front main beam
18 - Free 86 - R.H. front main beam
19 - Rear working tail light (option) 87 - Main beam indicator light
20 - Cab rear windscreen wiper 88 - Free
21 - Cab roof windscreen wiper (option) 89 - Free
22 - Cold start 90 - Levelling movement safety
23 - Engine stop electrovalve
24 - Revolving light COLOUR CODING
25 - Front wheels alignment detector bc : white bl : blue g : grey j : yellow
26 - Rear wheels alignment detector jvt : yellow/green m : brown n : black o : orange
27 - Moving speed limitation electrovalve r : red ro : pink vt : green v : purple
28 - Hydraulic engine rotation electrovalve
29 - L.H. rear reverse light CONECTOR
30 - R.H. rear reverse light A - Fuse box / relay (13 pin connection)
31 - Reverse gear sound alarm (option) B - Fuse box / relay (13 pin connection)
32 - Forward electrovalve C - Fuse box / relay (13 pin connection)
33 - Reverse electrovalve D - Fuse box / relay (6 pin connection)
34 - Low speed indicator light E - Fuse box / relay (8 pin connection)
35 - High speed indicator light F - Fuse box / relay (8 pin connection)
36 - High speed electrovalve G - Fuse box / relay (21 pin connection)
37 - High speed control relay H - Fuse box / relay (5 pin connection)
38 - Low speed control relay I - Fuse box / relay (8 pin connection)
39 - Starting safety relay J - Fuse box / relay (8 + 2 pin connection)
40 - Forward relay K - K1 relay predisposition (option)
41 - Free L - K0 relay predisposition (option)
42 - Reverse relay M - Predisposition (8 + 1 pin connection) (option)
43 - Rear reverse light relay N - Engine box
44 - Transmission cut-off relay O - Rear predisposition (8 pin connection) (option)
45 - Autoradio (option) P - Comodo
46 - Overload safety system Q - Heating ventilation
47 - Hydraulic movements cut-off (option) R - Air-conditionning (option)
48 - Sound alarm S - Cab
49 - L.H. stoplight T - Front windscreen wiper
50 - R.H. stoplight U - Overload strain gauge
51 - Free
52 - Blinking center / warning ELECTRIC COMPONENTS
53 - Blinking center / warning indicator light E1 - R.H. rear indicador
54 - R.H. rear indicador E2 - R.H. front indicador
55 - R.H. front indicador E3 - L.H. rear indicador
56 - L.H. rear indicador E4 - L.H. front indicador
57 - L.H. front indicador E5 - L.H. stoplight
58 - Warning / indicador light switch E6 - R.H. stoplight
59 - Roof light E7 - R.H. rear position light
60 - Ventilation E8 - R.H. front position light
61 - Air conditionning (option) E9 - L.H. rear position light
62 - Free E10 - L.H. front position light
63 - Free E11 - L.H. front low beam
64 - Free E12 - R.H. front low beam
65 - Rear desfrosting (option) E13 - L.H. front main beam
66 - Free E14 - R.H. front main beam
67 - Front windscreen washer E15 - R.H. rear working tail light (option)
4
E16 - L.H. rear working tail light (option) H19 - Ventilation indicator light
E17 - L.H. front working headlight (option) H20 - Low speed indicator light
E18 - R.H. front working headlight (option) H21 - High speed indicator light
E19 - Revolving light
E20 - L.H. reverse light K0 - Air-conditionning relay (option)
E21 - Roof light K1 - Free (option)
E22 - R.H. reverse light (option) K2 - Transmission cut-off relay
E23 - L.H. rear fog light K3 - Reverse relay
E24 - R.H. rear fog light K4 - Forward relay
K5 - Horn
FUSES K6 - Free (option)
F1 - Levelling safety (7.5A) K7 - Hydraulic movements cut-off (option)
F2 - Rear working tail light (option) (15A) K8 - Start safety relay
F3 - Rear / roof windscreen wiper (7.5A) K9 - Central intermitente / warning
F4 - Engine stop electrovalve (10A) K10 - Overload safety module
F5 - Revolving light (7.5A) K11 - Rear reverse light relay and buzzer/hydraulic engine
F6 - Wheels alignment (5A) rotation
F7 - Load status indicator device (10A) K12 - Free
F8 - Transmission cut-off gear reverser (15A) K13 - Low speed relay
F9 - Control panel (5A) K14 - High speed relay
F10 - Horn / stop switch (15A) K16 - Preheating relay
F11 - Free (15A max) K17 - Indicador light module relay
F12 - Indicador power supply (10A) K18 - Transmission cut-off module
F13 - Ventilation (30A)
F14 - Free (25A max) M1 - Starter
F15 - Free (25A max) M2 - Front windscreen wiper
F16 - Air-conditionning (option) (10A max) M3 - Windscreen washer
F17 - Free (15A max) M4 - Roof windscreen wiper (option)
F18 - Front working headlight (option) (15A) M5 - Horn
F19 - Rear desfrosting (option) (15A max) M6 - Ventilation
F20 - Free (10A max) M7 - Reverse gear sound alarm (option)
F21 - Front windscreen wiper and windscreen washer (10A) M8 - Rear windscreen wiper
F22 - Free (15A max) M9 - Fuel pump
F23 - R.H. position light + control panel lighting (7.5A)
F24 - L.H. position light (7.5A) P1 - Hourmeter module
F25 - R.H. indicadors (7.5A) P2 - Fuel level module
F26 - L.H. indicadors (7.5A) P3 - Engine water temperature module
F27 - Low beam (15A)
F28 - Main beam (15A) R1 - Preheating resistor
F29 - Warning + roof light (15A) R2 - Fuel sensor
F30 - Lighting switch, horn and indicadors (25A) R3 - Engine water temperature sensor
F31 - Starter (20A) R4 - Rear desfrosting resistor
F40 - Equipments (40A)
F41 - Equipments (40A) S1 - Key switch
F42 - Preheating (80A) S2 - Gear reverser
F43 - Alternator (80A) S3 - Engine oil pressure switch
S4 - Brake fluid
G1 - Battery S5 - Air filter clogging
G2 - Alternator S6 - Front wheels alignment sensor
S7 - Brake switch
H1 - Battery load indicator light S8 - Front windscreen wiper / windscreen washer switch
H2 - Engine oil pressure indicator light S9 - Horn control
H3 - Brake fluid indicator light S10 - Wheels alignment switch
H4 - Air/oil hydraulic return filter clogging indicator light S11 - Warning switch
H5 - Engine water temperature indicator light S12 - Free
H6 - Warning indicator light S13a - Position light (comodo)
H7 - Position light indicator light S13b - Low / main beam (comodo)
H8 - Free S13c - Indicadors (comodo)
H9 - Main beam indicator light S14 - Free
H10 - Warning indicator light S15 - Rear working tail light switch (option)
H11 - Front wheels alignment indicator light S16 - Stop switch
H12 - Free S17 - Free
H13 - Handbrake indicator light S18 - Front workling head light switch (option)
H14 - Rear wheels alignment indicator light S19 - Revolving light switch
H15 - Hourmeter module indicator light S20 - Rear/roof windscreen wiper
H16 - Engine water temperature module indicator light S21 - Ventilation switch
H17 - Fuel level module indicator light S22 - Overloas strain gauge
H18 - Low beam indicator light S23 - Hydraulic return filter clogging
5
S24 - Speed selector switch (high speed / low speed)

S25 - Transmission cut-off switch to accelerator pedal
S26 - Moving speed limitation switch
S27 - Rear wheels alignment sensor
S28 - Rear desfrosting switch (option)
S29 - Rear fog light switch (option)
S31 - Cold start switch
S32 - Jib head position switch
S33 - Switch on brake pedal
S34 - Seat sensor
V1 - Fault test diode

V2 - Diode (TUV)

Y4 - Cold start electrovalve
Y5 - Movement safety electrovalve
Y6 - High speed electrovalve
Y7 - Moving speed limitation electrovalve
Y8 - Hydraulic engine rotation electrovalve
6
ELECTRIC DIAGRAM MT 1033 HL TURBO SERIE 2-E2
S1 F9 E F1 F2 F3 F4 F5 F6 F8
r
J J J r
J A A A B B
I I I OP E r r j
j j
30 30 17 17 50 19 19 54 15 58
r r r r
K5 m ro o r H r S2
H1 H2 H3 H4 H5 H8 H12 H13 r r
S19 r
S10 K18
S15 S20 K11 K2 K14 B B
S25
j j j j
vi
or
B B B F E F E E F E E G
AV N AR B
F31 H H S33
B
B
N N bl g o n vt vt or r j j
N N N m n bc jvt bc vt o vt ro bl j g jvt g jvt m or
V1 V1 V1 V1 V1 V1 V1 V1 S26 S24 B B
ro
F40 F41 K8 I B I I I I I M
K4 K3 K13
m n
N N N L R
S7 S34
N n V1 g o n g vt
3,5s
n
F42 F43 M1 V1 V1 V1 V1 V1 r r
R3 R2 B S S S S S S N M S H H jvt
n bc ro
K16 G1
ro r m r bc bl bl bl bl bc vt o vt ro bl jvt j j j g m n m n m n or or bl ro or m r or jvt m m n or
P
N N N P P P S7 n
N S3 S4 S5 S23 T
N N K17 S31 jvt
jvt jvt G2 P1 K17
jvt
R1 R1 R1 R1 K16 P3 P2 jvt
E15 E16 M8 jvt M4 Y4 Y1 M9 E19 S6 H11 S27 H14 Y7 Y8 E20 E22 M7 Y2 Y3 H20 H21 Y6 K14 K13 K8 K4 K3 K11 K2
F jvt
J 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
J J
P F30
F7 F10 F11 P S13c F29 F12 F13 F16 F14 F15 F17 F19 F20 F21 F22 F18 o F1
S13a S13b J K
m o J r D v m m
H S22 G G B B A A B A A
vt vt r J o
j m r vt
P P Q S21 G L r r r
P P P
S11 S28 S18 j
K7 S16 M o m g n n ro A ro ro ro B bl j
A bc G G
K0
S9 n G r o vt r K6 K1
m bc vt J g r vt r g Q G Q m V2 r S29 S32
G M O S8 bl
F25 F26 v r m m o V2 G GG G
D D D D M M S M M F23 F24 F27 F28
g n R R L R J J o o
L
UUUUUU C C C C A D J JK K
H G I K9 S Q L T T T S C C C C C C C F C C F J K
E O O
r g J v bl n n vt r r jvt ro g g n n r J m m jvt n vt jvt ro r jvt m bl bl bl bl bl bl J J J jvt r bc bc bc J o m
G F O Q O G G
K10 K7 M5 E5 E6 H6 E1 E2 E3 E4 H10 E21 M6 K0 R4 M3 M2 E17 E18 H16 H17 H15 H7 E7 H19 E8 E9 E10 E11 E12 H18 E23 E24 E13 E14 H9 K6 K1 Y5
jvt
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
7
ELECTRIC DIAGRAM
80-6-268676 EN
15 / 11 / 2007
80-6-268676EN 2 15/11/2007
CONTENTS
-ELECTRIC DIAGRAM
MT 1033 H L Turbo Série 3-E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15/11/2007 3 70-6-268676EN
ÉLECTRIC DIAGRAM MT 1033 H L TURBO SÉRIE 3-E2
PRINCIPLE ELECTRIC CIRCUIT 58 - L.H. stoplight

59 - R.H. stoplight
1 - Power fuse 60 - Flasher unit / warning unit
2 - Starting safety relay 61 - Flashing light / warning unit indicator light
3 - Preheating relay 62 - R.H. rear indicator
4 - Starter 63 - R.H. front indicator
5 - Battery 64 - L.H. rear indicator
6 - Water temperature Indicator 65 - L.H. front indicator
7 - Fuel level Indicator 66 - Warning unit / indicator light switch
8 - Brake oil pressure 67 - Roof light
9 - Alternator 68 - Clock
10 - Hourmeter / rev counter 69 - Ventilation
11 - Indicator light module relay 70 - Air conditioning (Option)
12 - Load battery indicator 71 - Free
13 - Engine oil pressure 72 - Rear defrosting
14 - Brake fluid 73 - Work headlight on jib (Option)
15 - Air / hydraulic filter clogging 74 - Front working headlight (Option)
16 - Engine water temperature 75 - Working tail light (Option)
17 - Free 76 - Clock indicator light
18 - Free 77 - Water temperature module lighting
19 - Hand brake 78 - Fuel level module lighting
20 - Front windscreen washer 79 - Rev counter module lighting
21 - Front windscreen wiper 80 - Position indicator light
22 - Rear windscreen wiper 81 - Rear right position light
23 - Roof windscreen wiper 82 - Plate light (Option)
24 - Side windscreen wiper 83 - Ventilator switch lighting
25 - Revolving light 84 - Front right position light
26 - Cold start-up 85 - Rear left position light
27 - Engine stop 86 - Front left position light
28 - Fuel pump 87 - L.H. low beam
29 - Front wheels alignment detector 88 - R.H. low beam
30 - Rear wheels alignment detector 89 - Low beam indicator light
31 - Free 90 - L.H. rear fog light (Option)
32 - Free 91 - R.H. rear fog light (Option)
33 - Free 92 - L.H. front main beam
34 - Pneumatic seat (Option) 93 - R.H. front main beam
35 - Autoradio (Option) 94 - Main beam indicator light
36 - Speed limitation electrovalve (Snail) 95 - Free
37 - Direction of rotation electrovalve of hydraulic 96 - Free
motor 97 - Levelling movement safety
38 - L.H. rear reverse light (Option)
39 - R.H. rear reverse light (Option)
40 - Reverse gear sound alarm (Option)
41 - Forward electrovalve COLOUR CODING
42 - Reverse electrovalve bc : White bl : Blue g : Grey
43 - Low speed light (Tortoise) j : Yellow jvt : Yellow/Green m : Brown
44 - High speed light (Hare) n : Black o : Orange r : Red
45 - High speed electrovalve ro : Pink vt : Green v : Purple
46 - High speed control relay
47 - Low speed control relay
48 - Forward relay CONNECTOR
49 - Starting safety relay
50 - Reverse relay A - Fuses box / relay (13 pin connection)
51 - Transmission cut-off AA - Autoradio
52 - Overload safety system AB - Screenwiper switch connector (9 ways + 2
54 - Hydraulic movement cut-off switch (Option) ways)
53 - Retracted jib switch (Option) B - Fuses box / relay (13 pin connection)
55 - Hydraulic movement shut-down disabling relay C - Fuses box / relay (13 pin connection)
(Option) D - Fuses box / relay (6 pin connection)
56 - Hydraulic movements cut-off electovalve E - Fuses box / relay (8 pin connection)
(Option) F - Fuses box / relay (8 pin connection)
57 - Sound alarm G - Fuses box / relay (21 pin connection)
80-6-268676EN 4 15/11/2007
H - Fuses box / relay (5 pin connection) F10 - Sound alarm/Stop switch (15A)
I - Fuses box / relay (7 pin connection) F11 - Work headlight on jib (15A)
J - Fuses box / relay (8 pin connection + 2 pin F12 - Indicator power supply (10A)
connection) F13 - Ventilation (30A)
K - Prearranged option relay K1 F14 - Free (10A)
L - Prearranged option relay K0 F15 - Free (25A Maxi)
M - Prearranged option (8 pin connection + 1 pin F16 - Air conditioning (Option) (7,5A)
connection) F17 - Free (15A)
N - Engine box F18 - Front working headlight (Option) (15A)
O - Prearranged option rear (Connection 8 pin) F19 - Rear defrosting (Option) (15A)
P - Light switch, Sound alarm and Indicator F20 - Pneumatic seat (10A)
Q - Heating ventilation F21 - Front windscreen wiper and Windscreen
R - Air conditioning (Option) washer (10A)
S - Cab F22 - Jib suspension (Option) (15A)
T - Front windscreen wiper F23 - Right position light + Control instruments panel
U - Strain gauge light (7.5A)
Z - Connection 16 pin (PCB Control panel) F24 - Left position light (7.5A)
F25 - R.H. indicators (7.5A)
F26 - L.H. indicators (7.5A)
ELECTRICS COMPONENTS F27 - Low beam(15A)
F28 - Main beam (15A)
E1 - R.H. rear indicator F29 - Warning unit + roof light (15A)
E2 - R.H. front indicator F30 - Light switch, Sound alarm et indicators (25A)
E3 - L.H. rear indicator F31 - Starter (20A)
E4 - L.H. front indicator F40 - Equipments (40A)
E5 - L.H. stoplight F41 - Equipments (40A)
E6 - R.H. stoplight F42 - Engine preheating (80A)
E7 - Rear right position light F43 - Alternator (80A)
E8 - Front right position light
E9 - Rear left position light
E10 - Front left position light G1 - Battery
E11 - L.H. front low beam G2 - Alternator
E12 - R.H. front low beam
E13 - L.H. front main beam
E14 - R.H. front main beam H10 - Warning unit indicator light
E15 - R.H. working tail light (Option) H11 - Front wheels alignment indicator light
E16 - L.H. working tail light (Option) H14 - Rear wheels alignment indicator ligh
E17 - L.H. front working headlight (Option) H15 - Hourmeter / rev counter module indicator light
E18 - R.H. front working headlight (Option) H16 - Engine water temperature module indicator
E19 - Revolving light light
E20 - L.H. rear reverse light (Option) H17 - Fuel level module indicator light
E21 - Roof light H19 - Ventilation indicator light
E22 - R.H. rear reverse light (Option) H20 - Low speed light (Tortoise)
E23 - L.H. rear fog light H21 - High speed light (Hare)
E24 - R.H. rear fog light H22 - Clock light
E25 - Left work headlight on jib (Option)
E26 - Right work headlight on jib (Option)
E27 - Number plate lighting (Option) K0 - Air conditioning relay (Option)
K1 - Free
K2 - Transmission cut-off relay
FUSES K3 - Reverse relay
K4 - Forward relay
F1 - Leveling safety system (7.5A) K5 - Buzzer
F2 - Working tail light (Option) (15A) K6 - Free (Option)
F3 - Rear windscreen wiper/roof windscreen wiper K7 - Hydraulics movements cut-off (Option)
(7,5A) K7a - Movement forcing switch relay
F4 - Engine stop electrovalve (10A) K8 - Starting safety relay
F5 - Revolving light (7.5A) K9 - Warning centre / blinker
F6 - Wheels alignment (5A) K10 - Overload safety module
F7 - Load status indicator device (10A) K11 - Rear reverse light relay and Sound alarm
F8 - Gear reverser transmission cut-off (15A) /direction of rotation motor
F9 - Fault sound alarm light (5A) K13 - Low speed relay (Tortoise)
15/11/2007 5 70-6-268676EN
K14 - High speed relay (Hare) S30 - Steering pressure

K16 - Preheating relay S31 - Cold start-up switch
K17 - Indicator light module relay S36 - Seat switch
K18 - Transmission cut-off module S37 - Slope switch
S32 - Jib angular switch
S39 - Pneumatic seat switch
M1 - Starter S40 - Cigar lighter time lag switch
M2 - Front windscreen wiper S41 - Rear hydraulic control cut-off switch (Option)
M3 - Windscreen washer S42 - Hydraulic movement shut-down disabling
M4 - Roof windscreen wiper (Option) switch (Option)
M5 - Sound alarm S43 - Retracted telescope switch (Option)
M6 - Ventilation S44 - Retracted telescope switch (Option)
M7 - Reverse gear sound alarm S45 - Reverse tilt switch/forward tilt switch
M8 - Rear windscreen wiper S46 - Arm lowering switch (option)
M9 - Fuel pump S47 - Attachment switch (Option)
M10 - Side windscreen wiper
M11 - Pneumatic seat compressor
V1 - Diode
P1 - Hourmeter module V2 - Diode (TUV)
P2 - Fuel level module V3 - Battery load indicator light diode
P3 - Engine water temperature module V4 - Engine oil pressure indicator light diode
V5 - Engine water temperature indicator light diode
V6 - Air filter / hydraulic return filter clogging
R1 - Preheating resistor indicator light diode
R2 - Fuel sensor V7 - Transmission oil pressure indicator light diode
R3 - Engine water temperature sensor V8 - Transmission oil temperature indicator light
diode
V9 - Brake fluid indicator light diode
S1 - Key switch V10 - Brake indicator light diode
S2 - Gear reverser V11 - Flashing lights / warning unit indicator light
S3 - Engine oil pressure switch diode
S4 - Brake fluid V12 - Position indicator light diode
S5 - Air filter clogging V13 - Low beam indicator light diode
S6 - Front wheels alignment switch V14 - Main beam indicator light diode
S7 - Hand brake switch V15 - Fault direction light diode
S8 - Windscreen wiper / front windscreen washer
switch
S9 - Sound alarm control Y1 - Engine stop electrovalve
S10 - Wheels alignment switch Y2 - Forward electrovalve
S11 - Warning unit switch Y3 - Reverse electrovalve
S12 - Transmission oil pressure Y4 - Cold start-up electrovalve
S13a - Position light switch Y5 - Movement safety electrovalve
S13b - Low beam / main beam switch Y6 - High speed electrovalve (hare)
S13c - Indicator switch Y7 - Speed limitation electrovalve (snail)
S14 - Free Y8 - Direction of rotation electrovalve of hydraulic
S15 - Front / back working headlight switch (Option) motor
S16 - Stop switch Y9 - Hydraulics movements cut-off electrovalve
S17 - Free (Option)
S18 - Work headlight on jib switch (Option)
S19 - Revolving light switch
S20 - Rear / roof windscreen wiper switch
S21 - Ventilation switch
S22 - Overload strain gauge
S24 - High/low speed selection switch (hare/tor-
toise)
S25 - Switch on accelerator pedal
S26 - Speed limitation switch (snail)
S27 - Rear wheels alignment switch
S28 - Rear defrosting switch (Option)
S29 - Rear fog light switch
80-6-268676EN 6 15/11/2007
ELECTRIC DIAGRAM MT 1033 H L TURBO SÉRIE 3-E2
Fus.Therm.
S1 F9 2A E Z F3 F21 F5 F4 F6 F14
r
J J J J
A B A A B B
I I I OP
E Z
30 30 17 17 50 19 19 54 15 58 K5 Z r
V4 V9 V6 V5 V8 V7 V10
EG Latéral
j j r r r r V3 AB AB AB S r
Z Z Z Z Z Z Z S10
EG Toitl
vi B B B F AB
j j j j or E F E E F E E SWF 521 243 SWF 521 005
+
N F31 S8 AB
+
SWF 596 307 SWF 596 628
N N N bl g o n vt v 01 0 1 02 3 74 8 9 5 9
N B Z V1 V1
m n j g jvt m
V1 V1 V1 V1 V1 V1 1 52 6 10 1 0 1 10
K8 I B I I I I I F S20 S19 D D
F40 F41
N N N
B n V1 3,5s AB AB
g o n g vt n
F42 F43 M1 V1 V1 V1 V1 V1 AB S AB
N R3 R2 V15 B AB
E19 N M
n bc G1 Z
T T T
K16 T M4 M10
ro r m r bc bl bl bl bl P S j j j m n m n
N raz
4 2 2 vit 1 S raz
4 2 vit 1 raz
4 2 vit 1 raz
4 2 2 vit1
N N P P P S7
+perm +perm +perm +perm
M M
AR M
TOIT M
LAT T
K16 N
P S3 S4 S5 S23 M3 3 - 3 - 3 - 3 -
N N P1 K17 M2 AV 1
M8
1 1 1
S31
jvt jvt S30 G2 T S S
jvt K17
R1 R1 R1 R1 P3 P2 Y4 Y1 M9 S6 H11 S27 H14
jvt
F
J jvt
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
F15 F17 F20 F8 F7 F10

r
A AA H bl S22 r P B
J G vt vt
r H r r B4 B2 S35
B5 B1
n ro A K11 K2 K14 r r
S2 r B3
PCB S16
AA S33
H H S25 S44 K7a K7 S9
o AA
+ +
or or
r R F
j
B7
or
B6
n
K18 r
G vt r
R S26 S24 PCB m m bc vt j g S43 S45 O
o v P
D D M M M -L S7 S32 b
A2 AA K4 K3 K13 vt
v
L R r r S46
Y9
S39 UUUUUU S47 o
H H H H H K7a
j/v I
ro
n
jvt ro J n
AA AA m n or or bl ro or m r or jvt m m jvt r g j v bl n j/v j/v vt r r
V G o
g G n I 0 II 1 7 2 8 10
M J jvt r
jvt
S42 3 6 9
M11 K10
Y7 Y8 E20 E22 M7 Y2 Y3 H20 H21 Y6 K14 K13 K4 K8 K3 K2 K7 M5 E5 E6
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
P F30
P F29 F12 F13 F16 F22 F19 F11 F18 F2 o F1
S13c S13a S13b J K
m o J r D v m m A B A A A
r S Ep1 cab S S S J o
P P Q A G L SWF 521 008
+ SWF 521 110 SWF 521 054
+
P P P
S11 S21 SWF 596 390 +
SWF 596 473
SWF 596 151
j
bl j bc
o m g n K0 B 5 9
S18 S15 A G G
5 6 9 3 4 9
1 10
1 0
n Q G vt S28 1 0 1 7 2 8 10
2 01 1 7 2 8 10
r K6 K1
G Q V2 r S32
g S29
A v r m m o S V2 V2 G
F25 F26 M F23 F24 F27 F28 G G G
g n L R J J o o
E21 RR L S
C C C C J JK K
Q L C C C C C C C F O C C F J K
K9 E25 E26
E O O Dégivrage E17 E18 E15 E16 bl
J bc
vitre ar
jvt ro g g n n r m m bl F bl bl bl bl J J jvt r bc bc J o m
Z
Z H22 H16 Z Q O Z V14
S N G O V13 G G
V11 S S S S V12
S S Z
Z Z Z
E1 E2 E3 E4 H10 M6 K0 H17 H15 E7 E27 H19 E8 E9 E10 E11 E12 E23 E24 E13 E14 K6 K1 Y5
60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97
15/11/2007 7 80-6-268676EN
80-6-268676EN 8 15/11/2007
OPERATING AND SETTING OF THE
LONGITUDINAL STABILITY ALARM
80-8-80EN
07 / 10 / 2004
OPERATING AND SETTING OF THE LONGITUDINAL STABILITY ALARM
OPERATOR UNIT VISUAL DISPLAY AUDIO SIGNAL
Switch the machine

on All the LEDS are on
Engine turning over
To position "0", machine :

- Stable (no movement) Start of setting
- With no attachments
- Jib raised to max., telescope
retracted
- On wheels (stabilizers raised)
- Wheels aligned
- On machines fitted withtilting
corrector.
- Frame an horizontal position.
Press for 2 s the adjust button

located at the back of the unit
(see diagram 2)
2 yellow LEDS and 2

Enter set mode green LEDS in the
middle flash alternately
2 green LEDS at the bottom

Press the "STOP remain on
BUZZER" button
5 beeps indicate that the setting

"O" setting saved has been saved
To position "MAX":
Jib on horizontal position.
Take the machine's rated load, 2 red LEDS at the top remain
position it at max. startup as on
indicate on load chart minus
100mm. 2 yellow LEDS and 2
green LEDS in the
middle flash alternately
Press the "TEST"

button
5 beeps indicate that the setting

"MAX" setting saved has been saved
setting The unit returns to the

conforms "locked" position Operator starts setting over
consistency NO again
All the LEDS are on, with
"MAX" and "0" no buzzer ignition on
A continuous 2s beep
YES indicates to the operator that
the settings have been taken
into account and that the unit
is passing automatically into
The unit automatically leaves the set
the normal operation position
position the LEDS stop coming on
End of setting
Check the setting against the load

chart : put the rated load at max.
startup
setting
conforms Operator starts setting over
to load NO again
chart
The LEDS come on up to
YES the first red LED
Stick on the other part of the

"SESALY" sticker to seal the setting
(see diagram 2)
The operator can put the truck in the

desired position
3
WARNING
1 - This setting must be made with the rear axle assembly at a stable temperature.
Do not carry out after braking tests as the temperature difference between the
axle assembly and the gauge would disturb the setting.
2 - Before setting the unit, it is important to operate the machine for placing the strain
gauge (for example, when testing the machine, in which case make sure to
comply with point N° 1).
3 - Last checking of setting must be done before forwarding the machine
DIAGRAM 1 DIAGRAM 2
Place the sticker after setting and

1 red LED conformity checks
(To change at each setting)
2 red LEDS
2 yellow LEDS
4 green LEDS
Set button clearance hole

(tool Ø 2, min. length 40)
4
SAFETY SYSTEM
2 red LEDS
Test switch
Sound alarm signal light off
2 yellow LEDS Sound alarm

off switch
4 green LEDS
Power supply connector +

aggravating movements cut-off
signal output
Connection to the strain

gauge adjustment microswitch (accessible with a 6 mm
male hexagonal wrench)
5
INSPECTION PROCEDURE FOR THE LONGITUDINAL STABILITY ALARM STRAIN GAUGE
Connector engineering :
+ power supply red wire / contact N° 1

- power supply and PT 100 brown wire / contact N° 2
+ measurement yellow wire / contact N° 3
- measurement green wire / contact N° 4
PT 100 blue wire / contact N° 5
Shielding white / contact N° 6
Description of the connectors of strain gauge.
Shielding 6 + power supply 1
PT 100 5 - power supply 2
Measurement + 3
Measurement - 4
Prior to any electrical inspection, carry out a visual check on the state of the gauge and its
connections.
6
Electrical Inspection Fig.A Between A+ and A-
Disconnect the gauge from the electrical circuit.

Use a multimeter to take the following 350 Ω
measurements :
off 500Ω
5 KΩ
(Fig.A)
- Measure the impedance between A+ and A- =
Z power (power supply impedance)
Values : 300Ω ≤ Z power ≤ 400Ω
(Fig.B)
- Measure the impedance between M+ and M- =
Z meas. (measuring system impedance) Fig.B Between M+ and M-
Values : 300Ω ≤ Z power ≤ 400Ω
(Fig.C) 350 Ω
- Measure the impedance between A- and PT
off 500Ω
100 = Z PT100 5 KΩ
Values : 101Ω + 0.39xT
T corresponds to the gauge temperature.
Example : T=20°C then
Z PT 100 = 101Ω + 7.8Ω = 109Ω
(Fig.D)
- Measure the impedance between A+ and
shielding : Zbl Fig.C Between A- and PT100
Zbl > 30 MΩ (infinite resistance or open
circuit)
(Fig.E) 109 Ω
- Measure the impedance between A+ and the off 500Ω
5 KΩ
machine frame : Z frame
Z frame > 30 MΩ (infinite resistance or
open circuit)
Fig.D Betwen A+ and shielding Fig.E Between A+ and Frame
l l
off 500Ω off 500Ω
5 KΩ 5 KΩ
7
8

MLT 742 H T LS, Mt1033 HLT S2e2 S3e2 Repair Manual 547946en

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REPAIR MANUAL

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AXLE ASSEMBLY - AXLE

MLT 742 H T LSU

DIMENSIONS AND LOAD CHART 12

FILTERS CARTRIDGES AND BELTS 14

LUBRICANTS AND FUEL 16

FRONT AND REAR TYRES

- Level of sound power in the LwA environment 106 dB

- Average weighted acceleration on driver's body m/s2

- Speed of movement of lift truck in standard configuration on horizontal ground

- Standard lift height 6840 mm

- Rated capacity with standard attachment 4200 kg

- Load center 500 mm

- Weight of forks (each) 71 kg

- Lifting motions (jib retracted)

- Telescoping motions (lifting jib)

- Reverse tilt time unladen 3,5 s 41,6 °/s

- Forward tilt time unladen 3,0 s 48,6 °/s

- Lift truck weight with standard attachment

- Axle weight with attached equipment (transport position)

- Tensible strain at coupling hook

- Break out force with bucket 5550 daN

FRONT AND REAR TYRES

- Level of sound power in the LwA environment 106 dB

- Average weighted acceleration on driver's body m/s2

- Speed of movement of lift truck in standard configuration on horizontal

- Standard lift height 9610 mm

- Rated capacity with standard attachment 3300 kg

- Load center 500 mm

- Weight of forks (each) 68 kg

- Lifting motions (jib retracted)

- Telescoping motions (lifting jib)

- Reverse tilt time unladen 3s 41,9 °/s

- Forward tilt time unladen 2,5 s 50,3 °/s

- Lift truck weight with standard attachment

- Axle weight with attached equipment (transport position)

- Tensible strain at coupling hook

- Break out force with bucket 6600 daN

DRY AIR FILTER CARTRIDGE

SAFETY DRY AIR FILTER CARTRIDGE COMPRESSOR BELT

FUEL FILTER CARTRIDGE CYCLONIC PREFILTER

AUTOMATIC VACUUM-CLEANING PRE-FILTER

DISTRIBUTOR CONTROL HEAD FILTER

I.C. ENGINE OIL FILTER

DRY AIR FILTER CARTRIDGE

SAFETY DRY AIR FILTER CARTRIDGE COMPRESSOR BELT

FUEL FILTER CARTRIDGE CYCLONIC PRE-FILTER

AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION)

HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE (15µ)

FILTER CAP FOR HYDRAULIC OIL TANK

USE THE RECOMMENDED LUBRICANTS AND FUEL:

DIAGNOSTIC ANALYSIS OF OILS

(*) FUEL CHARACTERISTICS

CHARACTERISTICS OF RECOMMENDED FUEL:

USE THE RECOMMENDED LUBRICANTS AND FUEL:

DIAGNOSTIC ANALYSIS OF OILS

(*) FUEL CHARACTERISTICS

CHARACTERISTICS OF RECOMMENDED FUEL:

DIMENSIONS AND LOAD CHART 10

FILTERS CARTRIDGES AND BELTS 12

LUBRICANTS AND FUEL 14

MT 1033 H L Turbo Série 3-E2